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PC45MR-5 30001 and UP - PC55MR-5 20001 and UP SEN06574-07

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78% found this document useful (9 votes)

8K views1,215 pages

PC45MR-5 30001 and UP - PC55MR-5 20001 and UP SEN06574-07

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SEN06574-07

COMPACT PC45MR -5
HYDRAULIC
EXCAVATOR
PC55MR -5
PC45MR- 30001
SERIAL NUMBERS and up
PC55MR- 20001
00 INDEX AND FOREWORD

PC45MR-5, PC55MR-5 00-1

INDEX 00 INDEX AND FOREWORD

INDEX
00 INDEX AND FOREWORD ........................................................................................................................ 00-1
ABBREVIATION LIST ............................................................................................................................00-11
FOREWORD, SAFETY, BASIC INFORMATION ................................................................................... 00-17
HOW TO READ THE SHOP MANUAL........................................................................................... 00-17
SAFETY NOTICE FOR OPERATION............................................................................................. 00-19
PRECAUTIONS TO PREVENT FIRE............................................................................................. 00-27
ACTIONS IF FIRE OCCURS ......................................................................................................... 00-29
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS ........................................................ 00-30
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT ...................................................... 00-31
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS................................ 00-34
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT..................................................... 00-41
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT .................................................. 00-43
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT .............................................. 00-44
PRACTICAL USE OF KOMTRAX .................................................................................................. 00-45
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER ................................................... 00-46
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS ..................... 00-50
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR ..................... 00-54
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR ....... 00-55
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL ... 00-57
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH .. 00-58
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE .
................................................................................................................................................... 00-60
HOW TO READ ELECTRICAL WIRE CODE ................................................................................. 00-61
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD.................................................... 00-65
STANDARD TIGHTENING TORQUE TABLE................................................................................. 00-68
CONVERSION TABLE ................................................................................................................... 00-75
01 SPECIFICATIONS .................................................................................................................................... 01-1
CONTENTS ............................................................................................................................................ 01-2
ABBREVIATION LIST ............................................................................................................................. 01-3
SPECIFICATIONS .................................................................................................................................. 01-9
SPECIFICATION DRAWING............................................................................................................ 01-9
WORKING RANGE DRAWINGS ................................................................................................... 01-13
SPECIFICATIONS ......................................................................................................................... 01-15
WEIGHT TABLE ............................................................................................................................ 01-23
TABLE OF FUEL, COOLANT, AND LUBRICANTS ........................................................................ 01-27
10 STRUCTURE AND FUNCTION ................................................................................................................ 10-1
CONTENTS ............................................................................................................................................ 10-2
ABBREVIATION LIST ............................................................................................................................. 10-4
BOOT-UP SYSTEM .............................................................................................................................. 10-10
LAYOUT DRAWING OF BOOT-UP SYSTEM................................................................................. 10-10
SYSTEM OPERATING LAMP SYSTEM ........................................................................................ 10-12
BATTERY DISCONNECT SWITCH ............................................................................................... 10-14
ENGINE SYSTEM ................................................................................................................................ 10-15
LAYOUT DRAWING OF ENGINE SYSTEM ................................................................................... 10-15
ENGINE CONTROL SYSTEM ....................................................................................................... 10-16
AUTO-DECELERATION SYSTEM ................................................................................................. 10-20
OVERHEAT PREVENTION SYSTEM ............................................................................................ 10-22
AUTOMATIC IDLE STOP SYSTEM ............................................................................................... 10-24
COMPONENT PARTS OF ENGINE SYSTEM ............................................................................... 10-26
COOLING SYSTEM.............................................................................................................................. 10-27
LAYOUT DRAWING OF COOLING SYSTEM ................................................................................ 10-27
CONTROL SYSTEM............................................................................................................................. 10-29
LAYOUT DRAWING OF CONTROL SYSTEM ............................................................................... 10-29
MACHINE MONITOR SYSTEM ..................................................................................................... 10-30
KOMTRAX SYSTEM...................................................................................................................... 10-31
COMPONENT PARTS OF CONTROL SYSTEM............................................................................ 10-32

00-2 PC45MR-5, PC55MR-5

00 INDEX AND FOREWORD INDEX

HYDRAULIC SYSTEM.......................................................................................................................... 10-48

LAYOUT DRAWING OF HYDRAULIC SYSTEM ............................................................................ 10-48
CLSS ............................................................................................................................................. 10-50
ENGINE AND PUMP COMBINED CONTROL SYSTEM................................................................ 10-53
COMPONENT PARTS OF HYDRAULIC SYSTEM ........................................................................ 10-56
WORK EQUIPMENT SYSTEM ............................................................................................................10-118
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM ..............................................................10-118
STRUCTURE OF VALVE CONTROL............................................................................................10-122
PPC LOCK SYSTEM ....................................................................................................................10-124
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM ..............................................10-126
OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT.................................................................10-127
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM ...........................................................10-129
SWING SYSTEM .................................................................................................................................10-145
LAYOUT DRAWING OF SWING SYSTEM ...................................................................................10-145
COMPONENT PARTS OF SWING SYSTEM................................................................................10-146
TRAVEL SYSTEM................................................................................................................................10-156
LAYOUT DRAWING OF TRAVEL SYSTEM ..................................................................................10-156
TRAVEL CONTROL SYSTEM DIAGRAM .....................................................................................10-158
COMPONENT PARTS OF TRAVEL SYSTEM ..............................................................................10-160
UNDERCARRIAGE AND FRAME........................................................................................................10-171
LAYOUT DRAWING OF UNDERCARRIAGE ................................................................................10-171
IDLER CUSHION ..........................................................................................................................10-172
WORK EQUIPMENT............................................................................................................................10-173
STRUCTURE OF WORK EQUIPMENT ........................................................................................10-173
FUNCTION OF WORK EQUIPMENT ...........................................................................................10-174
WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM............................................................10-175
CAB AND ITS ATTACHMENTS ...........................................................................................................10-176
ROPS CAB ...................................................................................................................................10-176
TILT TYPE FLOOR .......................................................................................................................10-177
20 STANDARD VALUE TABLE ...................................................................................................................... 20-1
CONTENTS ............................................................................................................................................ 20-2
ABBREVIATION LIST ............................................................................................................................. 20-3
STANDARD VALUE TABLE FOR ENGINE ............................................................................................. 20-9
STANDARD VALUE TABLE FOR ENGINE: PC45MR-5................................................................... 20-9
STANDARD VALUE TABLE FOR ENGINE: PC55MR-5..................................................................20-11
STANDARD VALUE TABLE FOR MACHINE......................................................................................... 20-13
STANDARD VALUE TABLE FOR MACHINE: PC45MR-5 .............................................................. 20-13
STANDARD VALUE TABLE FOR MACHINE: PC55MR-5 .............................................................. 20-25
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE ......................... 20-37
30 TESTING AND ADJUSTING ..................................................................................................................... 30-1
CONTENTS ............................................................................................................................................ 30-2
ABBREVIATION LIST ............................................................................................................................. 30-5
RELATED INFORMATION ON TESTING AND ADJUSTING .................................................................30-11
TOOLS FOR TESTING AND ADJUSTING......................................................................................30-11
SKETCH OF TOOLS FOR TESTING AND ADJUSTING ............................................................... 30-15
ENGINE AND COOLING SYSTEM....................................................................................................... 30-17
TEST ENGINE SPEED .................................................................................................................. 30-17
TEST EXHAUST GAS COLOR ...................................................................................................... 30-19
TEST AND ADJUST VALVE CLEARANCE .................................................................................... 30-21
TEST COMPRESSION PRESSURE.............................................................................................. 30-23
TEST ENGINE OIL PRESSURE .................................................................................................... 30-25
BLEED AIR FROM FUEL SYSTEM ............................................................................................... 30-27
TEST FUEL CIRCUIT FOR LEAKAGE .......................................................................................... 30-29
HANDLE CYLINDER CUT-OUT MODE OPERATION.................................................................... 30-30
TEST AND ADJUST ALTERNATOR BELT TENSION .................................................................... 30-31
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION ................................. 30-32
POWER TRAIN..................................................................................................................................... 30-34
TEST SWING CIRCLE BEARING CLEARANCE ........................................................................... 30-34

PC45MR-5, PC55MR-5 00-3

INDEX 00 INDEX AND FOREWORD

UNDERCARRIAGE AND FRAME......................................................................................................... 30-35

TEST AND ADJUST TRACK TENSION......................................................................................... 30-35
HYDRAULIC SYSTEM.......................................................................................................................... 30-37
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM............................................. 30-37
TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, TRAVEL, AND BOOM SWING CIR-
CUITS ........................................................................................................................................ 30-43
TEST AND ADJUST SWING AND BLADE CIRCUIT OIL PRESSURE .......................................... 30-54
TEST AND ADJUST OIL PRESSURE OF CONTROL CIRCUIT .................................................... 30-61
ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT....................................................... 30-65
TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT..................................... 30-67
TEST OUTLET PRESSURE OF SOLENOID VALVE ..................................................................... 30-71
TEST PPC VALVE OUTLET PRESSURE ...................................................................................... 30-74
ADJUST WORK EQUIPMENT AND SWING PPC VALVES ........................................................... 30-79
TEST SWING PARKING BRAKE RELEASE PRESSURE ............................................................. 30-80
TEST AND ADJUST TRAVEL DEVIATION .................................................................................... 30-82
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT................................. 30-85
TEST OIL LEAKAGE ..................................................................................................................... 30-87
BLEED AIR FROM HYDRAULIC CIRCUIT .................................................................................... 30-90
PRESSURIZE HYDRAULIC TANK ................................................................................................ 30-93
CAB AND ITS ATTACHMENTS ............................................................................................................ 30-94
METHOD FOR OPENING AND CLOSING FLOOR UNIT .............................................................. 30-94
ELECTRICAL SYSTEM .......................................................................................................................30-104
SET AND OPERATE MACHINE MONITOR..................................................................................30-104
METHOD FOR STARTING UP KOMTRAX TERMINAL ................................................................30-155
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER .........................................................30-160
TEST DIODES ..............................................................................................................................30-161
40 TROUBLESHOOTING .............................................................................................................................. 40-1
CONTENTS ............................................................................................................................................ 40-2
ABBREVIATION LIST ............................................................................................................................. 40-6
RELATED INFORMATION ON TROUBLESHOOTING ......................................................................... 40-12
GENERAL TROUBLESHOOTING POINTS ................................................................................... 40-12
SEQUENCE OF EVENTS IN TROUBLESHOOTING..................................................................... 40-13
CHECKS BEFORE TROUBLESHOOTING .................................................................................... 40-15
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING ..................................................... 40-17
TESTING IN ACCORDANCE WITH TESTING PROCEDURE....................................................... 40-19
ELECTRICAL SYSTEM TROUBLESHOOTING - PREPARATION ................................................. 40-53
PROCEDURE FOR TESTING AND TROUBLESHOOTING .......................................................... 40-56
SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS ............................................. 40-59
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE.................................................... 40-63
CONNECTORS LIST AND LAYOUT.............................................................................................. 40-65
CONNECTOR CONTACT IDENTIFICATION (FOR 4D88E-7 ENGINE) ......................................... 40-81
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE ................................................................... 40-85
FUSE LOCATION TABLE .............................................................................................................. 40-91
FAILURE CODES TABLE .............................................................................................................. 40-95
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) .....................................................40-105
FAILURE CODE [989L00] .............................................................................................................40-105
FAILURE CODE [989M00] ............................................................................................................40-106
FAILURE CODE [989N00] ............................................................................................................40-107
FAILURE CODE [AQ20R1] ...........................................................................................................40-108
FAILURE CODE [B@BCNS] .........................................................................................................40-109
FAILURE CODE [D19JKZ] ............................................................................................................40-110
FAILURE CODE [D811MC] ...........................................................................................................40-113
FAILURE CODE [D862KA]............................................................................................................40-114
FAILURE CODE [D8ALKA] ...........................................................................................................40-115
FAILURE CODE [D8ALKB] ...........................................................................................................40-117
FAILURE CODE [D8AQKR] ..........................................................................................................40-119
FAILURE CODE [DAF0KT] ...........................................................................................................40-121
FAILURE CODE [DAF0MB] ..........................................................................................................40-122

00-4 PC45MR-5, PC55MR-5

00 INDEX AND FOREWORD INDEX

FAILURE CODE [DAF0MC] ..........................................................................................................40-123

FAILURE CODE [DAF3KK] ...........................................................................................................40-124
FAILURE CODE [DAF9KQ]...........................................................................................................40-126
FAILURE CODE [DAFGMC] .........................................................................................................40-127
FAILURE CODE [DAFLKA] ...........................................................................................................40-128
FAILURE CODE [DAFLKB] ...........................................................................................................40-130
FAILURE CODE [DAFQKR] ..........................................................................................................40-132
FAILURE CODE [DB2QKR] ..........................................................................................................40-133
FAILURE CODE [DBH0MC]..........................................................................................................40-137
FAILURE CODE [DBH2KK]...........................................................................................................40-138
FAILURE CODE [DBH5KP]...........................................................................................................40-141
FAILURE CODE [DBH5KP]...........................................................................................................40-143
FAILURE CODE [DBH9KQ] ..........................................................................................................40-145
FAILURE CODE [DBHLKA]...........................................................................................................40-147
FAILURE CODE [DBHLKB]...........................................................................................................40-149
FAILURE CODE [DBHQKR]..........................................................................................................40-151
FAILURE CODE [DDNRKA]..........................................................................................................40-156
FAILURE CODE [DDNRKY]..........................................................................................................40-158
FAILURE CODE [DDNS00]...........................................................................................................40-160
FAILURE CODE [DDWLKA]..........................................................................................................40-162
FAILURE CODE [DDWLKB]..........................................................................................................40-164
FAILURE CODE [DFB1KZ] ...........................................................................................................40-166
FAILURE CODE [DFB3L8]............................................................................................................40-168
FAILURE CODE [DFB5KZ] ...........................................................................................................40-170
FAILURE CODE [DHS1MA] ..........................................................................................................40-172
FAILURE CODE [DHS5MA] ..........................................................................................................40-174
FAILURE CODE [DKULKA]...........................................................................................................40-176
FAILURE CODE [DKULKB]...........................................................................................................40-178
FAILURE CODE [DKULKY]...........................................................................................................40-180
FAILURE CODE [DV00KB] ...........................................................................................................40-182
FAILURE CODE [DV20KB] ...........................................................................................................40-183
FAILURE CODE [DW43KA] ..........................................................................................................40-185
FAILURE CODE [DW43KB] ..........................................................................................................40-187
FAILURE CODE [DW43KY] ..........................................................................................................40-189
FAILURE CODE [DW4CKY]..........................................................................................................40-190
FAILURE CODE [DXA8KA]...........................................................................................................40-192
FAILURE CODE [DXA8KB]...........................................................................................................40-194
FAILURE CODE [DXE7KA]...........................................................................................................40-196
FAILURE CODE [DXE7KB]...........................................................................................................40-198
FAILURE CODE [DXE7KY]...........................................................................................................40-200
FAILURE CODE [DXEAKA] ..........................................................................................................40-202
FAILURE CODE [DXEAKB] ..........................................................................................................40-204
FAILURE CODE [DXEAKY] ..........................................................................................................40-206
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) ...........................................................40-208
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) ................................................40-208
E-2 ENGINE DOES NOT START (FUEL FEED PUMP SYSTEM) ................................................40-214
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK ....................................................40-216
E-4 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS
NOTHING..................................................................................................................................40-218
E-5 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUN-
NING .........................................................................................................................................40-221
E-6 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .................40-222
E-7 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING........................40-223
E-8 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUN-
NING .........................................................................................................................................40-224
E-9 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING ....40-225
E-10 FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM ...................40-226
E-11 DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL LEVEL.................................40-228

PC45MR-5, PC55MR-5 00-5

INDEX 00 INDEX AND FOREWORD

E-12 ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM
OR MAXIMUM...........................................................................................................................40-229
E-13 DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIFFERS FROM ACTUAL COOL-
ANT TEMPERATURE................................................................................................................40-230
E-14 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED ........................40-231
E-15 FUNCTION SWITCH DOES NOT OPERATE .......................................................................40-232
E-16 AUTO-DECELERATOR IS NOT OPERATED OR CANCELED WITH LEVER ......................40-233
E-17 WHEN WORKING MODE IS CHANGED, SETTING OF ENGINE AND HYDRAULIC PUMP IS
NOT CHANGED ........................................................................................................................40-234
E-18 WHEN TRAVEL SPEED SELECTION IS CHANGED, ACTUAL TRAVEL SPEED DOES NOT
CHANGE ...................................................................................................................................40-235
E-19 ALARM BUZZER DOES NOT SOUND.................................................................................40-237
E-20 ALARM BUZZER CANNOT BE CANCELED ........................................................................40-238
E-21 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION.........
..................................................................................................................................................40-239
E-22 SERVICE MODE CANNOT BE SELECTED .........................................................................40-240
E-23 ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHANISM DO NOT MOVE ......40-241
E-24 ALL OF WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT LOCK..........40-243
E-25 ALARM DOES NOT SOUND DURING TRAVEL ..................................................................40-245
E-26 ALARM DOES NOT STOP SOUNDING WHILE MACHINE IS STOPPED............................40-247
E-27 HORN DOES NOT SOUND..................................................................................................40-248
E-28 HORN DOES NOT SOUND (FOR PROPORTIONAL LEVER SPEC)...................................40-250
E-29 HORN DOES NOT STOP SOUNDING.................................................................................40-252
E-30 HORN DOES NOT STOP SOUNDING (FOR PROPORTIONAL LEVER SPEC) ..................40-254
E-31 WORKING LAMP OR TRAVEL LAMP DOES NOT LIGHT UP (CANOPY SPEC) ................40-256
E-32 NONE OF WORKING LAMP, TRAVEL LAMP, OR ADDITIONAL LAMP DOES NOT LIGHT UP
(CAB SPEC)..............................................................................................................................40-260
E-33 WHEN WIPER SWITCH IS OPERATED, WINDSHIELD WIPER DOES NOT OPERATE.....40-264
E-34 WHEN WINDOW WASHER SWITCH IS OPERATED, WINDOW WASHER DOES NOT OPER-
ATE ...........................................................................................................................................40-266
E-35 TRAVEL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .40-268
E-36 Swing or Arm IN IS NOT DISPLAYED NORMALLY IN MONITORING FUNCTION ..............40-269
E-37 Work Equipment IS NOT DISPLAYED NORMALLY IN MONITORING FUNCTION ..............40-270
E-38 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY ...................................................40-272
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) .......................40-273
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE).................................40-273
H-1 ALL WORK EQUIPMENT, TRAVEL, SWING OR BLADE DO NOT OPERATE.......................40-274
H-2 ALL WORK EQUIPMENTS OR TRAVEL DOES NOT OPERATE...........................................40-275
H-3 TRAVEL OR BLADE DOES NOT OPERATE..........................................................................40-276
H-4 SWING OR BLADE DOES NOT OPERATE ...........................................................................40-277
H-5 ALL WORK EQUIPMENT, TRAVEL, SWING AND BLADE SPEED OR POWER IS LOW ......40-278
H-6 ALL WORK EQUIPMENT AND TRAVEL SPEED OR POWER IS LOW .................................40-279
H-7 TRAVEL AND BLADE SPEED OR POWER IS LOW..............................................................40-280
H-8 SWING AND BLADE SPEED OR POWER IS LOW ...............................................................40-281
H-9 FINE CONTROL PERFORMANCE OR RESPONSE IS POOR..............................................40-282
H-10 UNUSUAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP ..................................40-283
H-11 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS...................................................40-284
H-12 ALL WORK EQUIPMENTS SPEED OR POWER IS LOW ...................................................40-286
H-13 ALL WORK EQUIPMENTS AND BLADE SPEED OR POWER IS LOW...............................40-287
H-14 BLADE DOES NOT OPERATE ............................................................................................40-288
H-15 ALL WORK EQUIPMENTS DO NOT OPERATE ..................................................................40-289
H-16 ALL WORK EQUIPMENTS OR BLADE DO NOT OPERATE ...............................................40-290
H-17 SPEED OR POWER OF BOOM IS LOW .............................................................................40-291
H-18 ARM SPEED OR POWER IS LOW ......................................................................................40-293
H-19 BUCKET SPEED OR POWER IS LOW................................................................................40-294
H-20 BLADE SPEED OR POWER IS LOW ..................................................................................40-295
H-21 BOOM SWING SPEED OR POWER IS LOW ......................................................................40-297
H-22 WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION .....................................40-298

00-6 PC45MR-5, PC55MR-5

00 INDEX AND FOREWORD INDEX

H-23 HYDRAULIC DRIFT OF BOOM IS LARGE ..........................................................................40-299

H-24 HYDRAULIC DRIFT OF ARM IS LARGE .............................................................................40-300
H-25 HYDRAULIC DRIFT OF BUCKET IS LARGE.......................................................................40-301
H-26 HYDRAULIC DRIFT OF BLADE IS LARGE .........................................................................40-302
H-27 TIME LAG OF WORK EQUIPMENT IS LARGE ...................................................................40-304
H-28 IN COMBINED OPERATION OF WORK EQUIPMENT, EQUIPMENT HAVING HEAVIER LOAD
MOVES SLOWER .....................................................................................................................40-305
H-29 MACHINE DOES NOT TRAVEL STRAIGHT ........................................................................40-306
H-30 MACHINE DOES NOT MOVE OFF STRAIGHT ...................................................................40-308
H-31 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW...............................40-309
H-32 TRAVEL SPEED IS LOW .....................................................................................................40-311
H-33 BOTH SIDES OF CRAWLERS DO NOT MOVE...................................................................40-313
H-34 ONE OF TRACKS DOES NOT RUN ....................................................................................40-314
H-35 TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO SLOW OR FAST ....40-316
H-36 UPPER STRUCTURE DOES NOT SWING BOTH TO THE RIGHT AND LEFT ...................40-317
H-37 SWINGS ONLY IN ONE DIRECTION...................................................................................40-319
H-38 SWING ACCELERATION OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND
LEFT) ........................................................................................................................................40-321
H-39 SWING ACCELERATION PERFORMANCE IS POOR OR SWING SPEED IS SLOW IN ONLY
ONE DIRECTION ......................................................................................................................40-323
H-40 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (BOTH
RIGHT AND LEFT)....................................................................................................................40-324
H-41 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (ONLY ONE
DIRECTION EITHER RIGHT OR LEFT)....................................................................................40-325
H-42 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWINGING ...............................40-326
H-43 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS SWINGING..40-327
H-44 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED).40-328
H-45 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED) ........
..................................................................................................................................................40-329
TROUBLESHOOTING OF ENGINE (S-MODE) ...................................................................................40-330
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE).................................40-330
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION.......
..................................................................................................................................................40-331
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT ...................................................40-332
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS
BUT DOES NOT START) ..........................................................................................................40-333
S-4 ENGINE STARTABILITY IS POOR.........................................................................................40-334
S-5 ENGINE DOES NOT PICK UP SMOOTHLY ..........................................................................40-336
S-6 ENGINE STOPS DURING OPERATION ................................................................................40-338
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE ..........................................................................40-339
S-8 ENGINE LACKS POWER.......................................................................................................40-340
S-9 KDPF GETS CLOGGED IN A SHORT TIME ..........................................................................40-342
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE ....................................................................40-343
S-11 OIL BECOMES CONTAMINATED QUICKLY ........................................................................40-344
S-12 FUEL CONSUMPTION IS EXCESSIVE ...............................................................................40-345
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) .......
..................................................................................................................................................40-346
S-14 OIL PRESSURE DROPS .....................................................................................................40-347
S-15 FUEL MIXES INTO ENGINE OIL..........................................................................................40-349
S-16 WATER MIXES INTO ENGINE OIL (MILKY) ........................................................................40-350
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) ......................................40-351
S-18 UNUSUAL NOISE IS HEARD...............................................................................................40-352
S-19 VIBRATION IS EXCESSIVE .................................................................................................40-353
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT...................................................................40-354
50 DISASSEMBLY AND ASSEMBLY............................................................................................................. 50-1
CONTENTS ............................................................................................................................................ 50-2
ABBREVIATION LIST ............................................................................................................................. 50-5
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY .........................................................50-11

PC45MR-5, PC55MR-5 00-7

INDEX 00 INDEX AND FOREWORD

HOW TO READ THIS MANUAL......................................................................................................50-11

COATING MATERIALS LIST.......................................................................................................... 50-13
SPECIAL TOOLS LIST .................................................................................................................. 50-17
SKETCHES OF SPECIAL TOOLS................................................................................................. 50-22
ENGINE AND COOLING SYSTEM....................................................................................................... 50-23
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY .................................................................. 50-23
REMOVE AND INSTALL STARTER ASSEMBLY ........................................................................... 50-30
REMOVE AND INSTALL RADIATOR ASSEMBLY ......................................................................... 50-32
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY ................................................ 50-39
REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY ................................................ 50-46
REMOVE AND INSTALL FUEL TANK ASSEMBLY ........................................................................ 50-59
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY ............................................................. 50-64
POWER TRAIN..................................................................................................................................... 50-65
REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY ................................ 50-65
REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY...................... 50-69
DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY .......................................... 50-71
REMOVE AND INSTALL SWING CIRCLE ASSEMBLY ................................................................. 50-78
UNDERCARRIAGE AND FRAME......................................................................................................... 50-80
DISASSEMBLE AND ASSEMBLE RECOIL SPRING..................................................................... 50-80
SEPARATION AND CONNECTION OF TRACK ASSEMBLY......................................................... 50-83
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY .................................................................. 50-85
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY ................................................. 50-88
DISASSEMBLEAND ASSEMBLE CARRIER ROLLER ASSEMBLY .............................................. 50-91
REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY ......................................................... 50-94
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY............................................................ 50-97
HYDRAULIC SYSTEM.........................................................................................................................50-105
REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY ..................................................50-105
DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY ...................................50-109
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY............................................................50-112
REMOVE AND INSTALL MAIN PUMP ASSEMBLY ......................................................................50-118
REMOVE AND INSTALL ACCUMULATOR ASSEMBLY ...............................................................50-124
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY ......................50-130
DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY ..........................................50-133
WORK EQUIPMENT............................................................................................................................50-136
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY .........................................................50-136
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY........................50-140
CAB AND ITS ATTACHMENTS ...........................................................................................................50-149
REMOVE AND INSTALL OPERATOR'S CAB ASSEMBLY (CAB SPEC) ......................................50-149
REMOVE AND INSTALL FLOOR FRAME ASSEMBLY (CANOPY SPEC)....................................50-156
REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS) ....................................50-162
REMOVE AND INSTALL FRONT WINDOW ASSEMBLY .............................................................50-172
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY .................................................50-175
REMOVE AND INSTALL OPERATOR'S SEAT .............................................................................50-184
REMOVE AND INSTALL SEAT BELT ...........................................................................................50-186
ELECTRICAL SYSTEM .......................................................................................................................50-187
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY ...................................................50-187
REMOVE AND INSTALL MACHINE CONTROLLER ASSEMBLY.................................................50-189
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY ........................................................50-192
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY......................................................50-195
60 MAINTENANCE STANDARD.................................................................................................................... 60-1
CONTENTS ............................................................................................................................................ 60-2
ABBREVIATION LIST ............................................................................................................................. 60-3
ENGINE AND COOLING SYSTEM......................................................................................................... 60-9
MAINTENANCE STANDARD FOR PTO .......................................................................................... 60-9
MAINTENANCE STANDARD OF COOLING SYSTEM .................................................................. 60-10
POWER TRAIN......................................................................................................................................60-11
MAINTENANCE STANDARD OF SWING CIRCLE .........................................................................60-11
MAINTENANCE STANDARD OF SWING MACHINERY................................................................ 60-12

00-8 PC45MR-5, PC55MR-5

00 INDEX AND FOREWORD INDEX

MAINTENANCE STANDARD OF SPROCKET .............................................................................. 60-14

UNDERCARRIAGE AND FRAME......................................................................................................... 60-15
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION.................................... 60-15
MAINTENANCE STANDARD OF IDLER ....................................................................................... 60-16
MAINTENANCE STANDARD OF TRACK ROLLER....................................................................... 60-18
MAINTENANCE STANDARD OF CARRIER ROLLER ................................................................... 60-19
MAINTENANCE STANDARD OF TRACK SHOE ........................................................................... 60-20
MAINTENANCE STANDARD OF TRIPLE SHOE........................................................................... 60-22
MAINTENANCE STANDARD OF ROAD LINER ............................................................................ 60-23
MAINTENANCE STANDARD FOR RUBBER SHOE...................................................................... 60-24
HYDRAULIC SYSTEM.......................................................................................................................... 60-25
MAINTENANCE STANDARD OF HYDRAULIC TANK ................................................................... 60-25
MAINTENANCE STANDARD OF MAIN PUMP.............................................................................. 60-26
MAINTENANCE STANDARD OF PC-EPC VALVE......................................................................... 60-28
MAINTENANCE STANDARD OF SWING MOTOR........................................................................ 60-29
MAINTENANCE STANDARD OF TRAVEL MOTOR ...................................................................... 60-31
MAINTENANCE STANDARD OF CONTROL VALVE..................................................................... 60-32
MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE ....................... 60-44
MAINTENANCE STANDARD OF BLADE PPC VALVE .................................................................. 60-47
MAINTENANCE STANDARD OF BOOM SWING PPC VALVE ...................................................... 60-49
MAINTENANCE STANDARD OF TRAVEL PPC VALVE ................................................................ 60-51
MAINTENANCE STANDARD OF ATTACHMENT PPC VALVE ...................................................... 60-54
MAINTENANCE STANDARD OF CENTER SWIVEL JOINT .......................................................... 60-56
WORK EQUIPMENT............................................................................................................................. 60-57
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE................................................. 60-57
MAINTENANCE STANDARD OF BOOM CYLINDER .................................................................... 60-68
MAINTENANCE STANDARD OF ARM CYLINDER ....................................................................... 60-69
MAINTENANCE STANDARD OF BUCKET CYLINDER................................................................. 60-71
MAINTENANCE STANDARD OF BLADE CYLINDER ................................................................... 60-73
MAINTENANCE STANDARD OF BOOM SWING CYLINDER ....................................................... 60-74
80 APPENDIX................................................................................................................................................ 80-1
CONTENTS ............................................................................................................................................ 80-2
ABBREVIATION LIST ............................................................................................................................. 80-3
AIR CONDITIONER SYSTEM ................................................................................................................ 80-9
PRECAUTIONS FOR REFRIGERANT ............................................................................................ 80-9
AIR CONDITIONER COMPONENT ............................................................................................... 80-10
SPECIFICATIONS OF AIR CONDITIONER ....................................................................................80-11
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE ............................................. 80-12
OUTLINE OF REFRIGERATION CYCLE ....................................................................................... 80-13
COMPONENT PARTS OF AIR CONDITIONER SYSTEM .................................................................... 80-15
AIR CONDITIONER UNIT.............................................................................................................. 80-15
COMPRESSOR ............................................................................................................................. 80-17
CONDENSER ................................................................................................................................ 80-19
RECEIVER DRIER......................................................................................................................... 80-20
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE........................................................... 80-21
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE).
.......................................................................................................................................................... 80-23
A-2 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS
ABNORMAL) ..................................................................................................................................... 80-26
A-3 TROUBLESHOOTING FOR TEMPERATURE CONTROL FUNCTION .......................................... 80-30
A-4 TROUBLESHOOTING FOR AIR CONDITINOER COMPRESSOR AND COOLING SYSTEM (ELEC-
TRICAL SYSTEM)............................................................................................................................. 80-33
A-5 TROUBLESHOOTING FOR AIR CONDITINOER COMPRESSOR AND COOLING SYSTEM (ME-
CHANICAL SYSTEMS) ..................................................................................................................... 80-37
A-6 TROUBLESHOOTING FOR HOT WATER CIRCUIT SYSTEM....................................................... 80-38
A-7 UNUSUAL NOISE IS HEARD FROM AIR CONDITINOER RELATED PARTS ............................... 80-39
A-8 WATER LEAKS FROM AIR CONDITINOER RELATED PARTS ..................................................... 80-40
A-9 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER............................................... 80-41

PC45MR-5, PC55MR-5 00-9

INDEX 00 INDEX AND FOREWORD

PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITION-
ER PIPINGS...................................................................................................................................... 80-42
HANDLE COMPRESSOR OIL .............................................................................................................. 80-44
90 CIRCUIT DIAGRAMS ............................................................................................................................... 90-1
CONTENTS ............................................................................................................................................ 90-2
ABBREVIATION LIST ............................................................................................................................. 90-3
HYDRAULIC CIRCUIT DIAGRAM .......................................................................................................... 90-9
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM .................................................................. 90-9
HYDRAULIC CIRCUIT DIAGRAM ................................................................................................. 90-13
HYDRAULIC CIRCUIT DIAGRAM (QUICK COUPLER SPECIFICATIONS) (1/2) .......................... 90-15
HYDRAULIC CIRCUIT DIAGRAM (QUICK COUPLER SPECIFICATIONS) (2/2) .......................... 90-17
ELECTRICAL CIRCUIT DIAGRAM ....................................................................................................... 90-19
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM............................................................... 90-19
ELECTRICAL CIRCUIT DIAGRAM (CANOPY SPEC) (1/5) ........................................................... 90-23
ELECTRICAL CIRCUIT DIAGRAM (CANOPY SPEC) (2/5) ........................................................... 90-25
ELECTRICAL CIRCUIT DIAGRAM (CANOPY SPEC) (3/5) ........................................................... 90-27
ELECTRICAL CIRCUIT DIAGRAM (CANOPY SPEC) (4/5) ........................................................... 90-29
ELECTRICAL CIRCUIT DIAGRAM (CANOPY SPEC) (5/5) ........................................................... 90-31
ELECTRICAL CIRCUIT DIAGRAM (CANOPY SPECIFICATIONS, QUICK COUPLER SPECIFICA-
TIONS) (1/5)............................................................................................................................... 90-33
ELECTRICAL CIRCUIT DIAGRAM (CANOPY SPECIFICATIONS, QUICK COUPLER SPECIFICA-
TIONS) (2/5)............................................................................................................................... 90-35
ELECTRICAL CIRCUIT DIAGRAM (CANOPY SPECIFICATIONS, QUICK COUPLER SPECIFICA-
TIONS) (3/5)............................................................................................................................... 90-37
ELECTRICAL CIRCUIT DIAGRAM (CANOPY SPECIFICATIONS, QUICK COUPLER SPECIFICA-
TIONS) (4/5)............................................................................................................................... 90-39
ELECTRICAL CIRCUIT DIAGRAM (CANOPY SPECIFICATIONS, QUICK COUPLER SPECIFICA-
TIONS) (5/5)............................................................................................................................... 90-41
ELECTRICAL CIRCUIT DIAGRAM (CAB SPEC) (1/6)................................................................... 90-43
ELECTRICAL CIRCUIT DIAGRAM (CAB SPEC) (2/6)................................................................... 90-45
ELECTRICAL CIRCUIT DIAGRAM (CAB SPEC) (3/6)................................................................... 90-47
ELECTRICAL CIRCUIT DIAGRAM (CAB SPEC) (4/6)................................................................... 90-49
ELECTRICAL CIRCUIT DIAGRAM (CAB SPEC) (5/6)................................................................... 90-51
ELECTRICAL CIRCUIT DIAGRAM (CAB SPEC) (6/6)................................................................... 90-53
ELECTRICAL CIRCUIT DIAGRAM (CAB SPECIFICATIONS, QUICK COUPLER SPECIFICATIONS)
(1/6)............................................................................................................................................ 90-55
ELECTRICAL CIRCUIT DIAGRAM (CAB SPECIFICATIONS, QUICK COUPLER SPECIFICATIONS)
(2/6)............................................................................................................................................ 90-57
ELECTRICAL CIRCUIT DIAGRAM (CAB SPECIFICATIONS, QUICK COUPLER SPECIFICATIONS)
(3/6)............................................................................................................................................ 90-59
ELECTRICAL CIRCUIT DIAGRAM (CAB SPECIFICATIONS, QUICK COUPLER SPECIFICATIONS)
(4/6)............................................................................................................................................ 90-61
ELECTRICAL CIRCUIT DIAGRAM (CAB SPECIFICATIONS, QUICK COUPLER SPECIFICATIONS)
(5/6)............................................................................................................................................ 90-63
ELECTRICAL CIRCUIT DIAGRAM (CAB SPECIFICATIONS, QUICK COUPLER SPECIFICATIONS)
(6/6)............................................................................................................................................ 90-65
INDEX..................................................................................................................................................................1

00-10 PC45MR-5, PC55MR-5

Symbols
Important safety and quality portions are marked with the following symbols so that shop manual is used effec-
tively.
Symbol Item Remark
This signal indicates an extremely hazardous situation which will result in
Danger
death or serious injury if it is not avoided.
This signal indicates a potentially hazardous situation which will result in
Warning
death or serious injury if it is not avoided.
This signal indicates a potentially hazardous situation which will result in
Caution
injury or property damage around the machine if it is not avoided.
This signal indicates the weight of parts and components, and items which
Weight requires great attention to a selection of wires and working posture for
slinging work.
This signal indicates the tightening torque for portions which requires spe-
Tightening torque
cial care in assembling work.
This signal indicates a place to be coated with adhesive, grease, etc. in
Coat
assembling work.

Oil and coolant This signal indicates a place to supply oil, coolant, etc. and the quantity.

Draining This signal indicates a place to drain oil, coolant, etc. and the quantity.

Signal word
Signal word for notice and remark describes the following.
Symbol Item Remark
If the precaution of this signal word is not observed, the machine damage
NOTICE Notice
or shortening of service life may occur.
REMARK Remark This signal word contains useful information to know.

Unit
International System of Units (SI) is used in this manual. For reference, units that have been used in the past
are given in { }.

00-18 PC45MR-5, PC55MR-5

00 INDEX AND FOREWORD SAFETY NOTICE FOR OPERATION

SAFETY NOTICE FOR OPERATION

• Appropriate servicing and repair are extremely important to ensure safe operation of the machine. The shop
manuals describe the effective and safe servicing and repair methods recommended by Komatsu. Some of
the servicing and repair methods require the use of special tools designed by Komatsu for special purpos-
es.

• The symbol mark is indicated for such matters that require special precautions. The work indicated with
this warning mark should be performed according to the instructions with special attention. Should a
hazardous situation occurs or be anticipated during such work, be sure to keep safe first and take every
necessary measures.
Safety matters
• Well organized work place
• Correct work clothes
• Observance of work standard
• Enforcement of hand signals
• Prohibition against unlicensed persons operating and handling the machine
• Safety check before starting work
• Wear of dust glasses (for cleaning or grinding work)
• Wear of welding goggles and protectors (for welding work)
• Being in good physical condition, and good preparation
• Always be alert and careful.
General precautions
k If the machine is handled incorrectly, it is dangerous. Read and understand what is described in the
operation and maintenance manual before operation. Read and understand what is described in this
manual before operation.
• Read and understand the meaning of all the safety labels stuck to the machine before performing any
greasing or repairs. For the locations of the safety labels and detailed explanation of precautions, see Oper-
ation and Maintenance Manual.
• Tools and removed parts in the workshop should be well organized. Always keep the tools and parts in their
correct places. Always keep the work area clean and make sure that there is no dust, dirt, oil, or water on
the floor. Smoke only in the designated areas. Never smoke while working.
• Keep all tools in good condition, learn the correct way to use them, and use the proper ones. Check the
tools, machine, forklift truck, service car, etc. thoroughly before starting the work.
• Always wear safety shoes and helmet when performing
any operation. Do not wear loose clothes, or clothes with
buttons missing.

PC45MR-5, PC55MR-5 00-19

SAFETY NOTICE FOR OPERATION 00 INDEX AND FOREWORD

• Always wear the protective eyeglasses when hitting parts

with a hammer.
• Always wear the protective eyeglasses when grinding
parts with a grinder, etc.
• When performing any operation with multiple workers, al-
ways agree on the operating procedure before starting. Be
clear in verbal communication, and observe hand signals.
Hang "UNDER REPAIR" warning tag in the operator's
compartment Before starting work. ,&
• Work and operation which require license or qualification
should be performed by qualified workers.
• Welding repairs should be performed by trained and experienced welders. When performing welding work,
always wear welding gloves, apron, welding goggles, cap and other clothes suited for welding work.
• Warm up before starting the work with exercise which increases alertness and the range of motion in order
to prevent injury.
• Avoid prolonged work, and take a rest at times to keep up a good condition. Take a rest at designated safe
area.
Precautions for preparatory work
• Place the machine on a firm and level ground, and apply the parking brake and chock the wheels or tracks
to prevent the machine from moving before adding oil or making any repairs.
• Lower the work equipment (blade, ripper, bucket, etc.) to the ground before starting work. If this is not pos-
sible, insert the lock pin or use blocks to prevent the work equipment from falling. In addition, be sure to
lock all the control levers and hang "UNDER REPAIR" warning tag on them.
• When performing the disassembling or assembling work, support the machine securely with blocks, jacks,
or stands before starting the work.
• Remove all mud and oil from the steps or other places for
going up and down on the machine. Always use the hand-
rails, ladders or steps when for going up and down on the
machine. Never jump on or off the machine. When the
scaffold is not provided, use steps or stepladder to secure
your footing. Do not use handrails, ladders, or steps if they
are damaged or deformed. Repair it or replace it immedi-
ately.

Precautions during work

• For the machine with the battery disconnect switch, check before starting the work that the system operat-
ing lamp is not lit. Then, turn the battery disconnect switch to OFF (○) position.
REMARK
Remove the key after it is turned to OFF (○) position if the battery disconnect switch is a switch key type.
For the machine without the battery disconnect switch, turn the starting switch to OFF position, wait for two
minutes or more before starting the work. Disconnect the battery cable by starting from the negative (-) ter-
minal first.
• For the machine with the quick release battery terminal (-), check before starting the work that the system
operating lamp is not lit. Then, disconnect the quick release battery terminal (-).
REMARK
For the machine without the system operating lamp, turn the starting switch to OFF position, wait for two
minutes or more before starting the work. Disconnect the quick release battery terminal (-).

00-20 PC45MR-5, PC55MR-5

00 INDEX AND FOREWORD SAFETY NOTICE FOR OPERATION

• Release the remaining pressure from the circuit before starting the work of disconnecting and removing of
oil, fuel, water, or air from the circuit. When removing the cap of oil filter, drain plug, or oil pressure plug, it
should be done slowly otherwise the oil spills.
• When removing or installing the checking plug or the piping in the fuel circuit, wait 30 seconds or longer
after the engine is shut down and start the work after the remaining pressure is released from the fuel cir-
cuit.
• The coolant and oil in the circuits are hot when the engine
is shut down. Be careful not to get scalded. Wait for the oil
and coolant to cool before performing any work on the oil
or coolant circuits.

• Before starting work, shut down the engine. When working

on or around a rotating part, in particular, shut down the
engine. When checking the machine without shutting down
the engine (measuring oil pressure, revolving speed, tem-
perature, etc.), take extreme care not to get caught in ro-
tating parts or moving parts.
• When raising a heavy component (heavier than 25 kg),
use a hoist or crane. Before starting work, check that the
slings (wire ropes, webbing slings, chains, and hooks) are
free from damage. Always use slings which have ample
capacity and install them to proper places. Operate the
hoist or crane slowly to prevent the component from hitting
any other part. Do not work with any part still raised by the
hoist or crane.
• When removing a part which is under internal pressure or
under reaction force of a spring, always leave 2 bolts in di-
agonal positions. Loosen those 2 bolts gradually and alter-
nately to release the pressure, and then remove the part.
• When removing components, do not break or damage the
electrical wiring. Damaged wiring may cause a fire.
,&
• When removing piping, do not spill the fuel or oil. If any
fuel or oil drips onto the floor, wipe it off immediately. Fuel
or oil on the floor can cause you to slip and can even cause fires.
• Do not use gasoline to wash parts as a general rule. Do not use gasoline to clean electrical parts, in partic-
ular.

PC45MR-5, PC55MR-5 00-21

SAFETY NOTICE FOR OPERATION 00 INDEX AND FOREWORD

• Be sure to assemble all parts again in their original places. Replace any damaged parts and parts which
must not be reused with new parts. When installing hoses and wiring harnesses, be sure that they will not
be damaged by contact with other parts when the machine is operated.
• When installing high pressure hoses and tubes, make sure that they are not twisted. Damaged hoses and
tubes are dangerous, so be extremely careful when installing hoses and tubes for high pressure circuits. In
addition, check that high pressure hoses and tubes are correctly installed.
• When assembling or installing parts, always tighten them to the specified torques. When installing protec-
tive parts such as guards, or parts which vibrate violently or rotate at high speed, check again that they are
installed correctly.
• Never insert your fingers or hand when aligning 2 holes. Be careful not to get your fingers caught in a hole.
• Check that the measuring tools are correctly installed when measuring hydraulic pressure.
• Take care when removing or installing the tracks of track-type machines. Since the track shoe may sepa-
rate suddenly when you remove it, never let anyone stand at either end of the track shoe.
• If the engine is operated for a long time in a closed place
with poor ventilation, it may cause gas poisoning. Open
the windows and doors to ventilate the place well.

Precautions for slinging work and making signals

• Only one appointed worker must make signals and co-workers must communicate with each other fre-
quently. The appointed signaler must make specified signals clearly at a place where he is well seen from
the operator's seat and where he can see the working condition easily. The signaler must always stand in
front of the load and guide the operator safely.
k Never stand under the load.
k Do not move a load over a person.
k Never step on the load.
k Do not prevent the load from swinging or falling down by holding it simply with the hands.
k The sling workers and assistant workers other than the guide must move to a place where they
are not caught between the load and materials or equipment on the ground or hit by the load
even if the crane starts abruptly.
• Check the slings before starting sling work.
• Keep putting on gloves during sling work. (Put on leather gloves, if available.)
• Measure the weight of the load by the eye and check its center of gravity.
• Use proper sling corresponding to the weight of the load and method of slinging. If too thick wire ropes are
used to sling a light load, the load may slip and fall.
• Do not sling a load with 1 wire rope alone. If it is slung so, it may rotate and may slip out of the rope. Install
2 or more wire ropes symmetrically.
k Slinging with one rope may cause turning of the load during hoisting, untwisting of the rope, or
slipping of the rope from its original slinging position on the load, which can result in a danger-
ous accident.
• Hanging angle must be 60 ° or smaller as a rule.
• When slinging a heavy load (25 kg or heavier), the hanging angle of the rope must be narrower than that of
the hook.

00-22 PC45MR-5, PC55MR-5

00 INDEX AND FOREWORD SAFETY NOTICE FOR OPERATION

REMARK
When slinging a load with 2 or more ropes, the force sub-
jected to each rope increases with the hanging angle. The
figure below shows the variation of allowable load in kN
{kg} when slinging is made with 2 ropes, each of which is
allowed to sling up to 9.8 kN {1000 kg} vertically, at vari-
ous hanging angles. When the 2 ropes sling a load verti-
cally, they can sling up to 2000 kg of total weight. This
weight is reduced to 1000 kg when the 2 ropes make a
hanging angle of 120 °. If the 2 ropes sling a 2000 kg load
at a hanging angle of 150 °, each rope is subjected to a
force as large as 39.2 kN {4000 kg} .
• When installing wire ropes to an angular load, apply pads to protect the wire ropes. If the load is slippery,
apply proper material to prevent the wire rope from slipping.
• Use the specified eye bolts and fix wire ropes, chains, etc. to them with shackles, etc.
• Apply wire ropes to the middle part of the hook.
k Do not use hooks if it does not have a latch sys-
tem.
k Slinging near the tip of the hook may cause the
rope to slip off the hook during hoisting.
REMARK
The strength of the hook is maximum at its central part.

• Never use a wire rope which has breaks in strands (A), re-
duced diameter (B), or kinks (C). There is a danger that
the rope may break during the towing operation.
Precautions for slinging up
• Wind in the crane slowly until wire ropes are stretched.
When settling the wire ropes with the hand, do not grasp
them but press them from above. If you grasp them, your
fingers may be caught.
• After the wire ropes are stretched, stop the crane and
check the condition of the slung load, wire ropes, and
pads.
• If the load is unstable or the wire rope or chains are twisted, lower the load and lift it up again.
• Do not lift up the load at an angle.
Precautions for slinging down
• When slinging down a load, stop it temporarily at 30 cm above the floor, and then lower it slowly.
• Check that the load is stable, and then remove the sling.
• Remove kinks and dirt from the wire ropes and chains used for the sling work, and put them in the specified
place.
Precautions for using mobile crane
REMARK
Read Operation and Maintenance Manual of the crane carefully in advance and operate the crane safely.
Precautions for using overhead traveling crane
k When raising a heavy component (heavier than 25 kg), use a hoist or crane.

PC45MR-5, PC55MR-5 00-23

SAFETY NOTICE FOR OPERATION 00 INDEX AND FOREWORD

REMARK

Weight of component whose weight is heavier than 25 kg is shown with symbol in "DISASSEMBLY AND
ASSEMBLY".
• Before starting work, check the wire ropes, brake, clutch, controller, rails, over winding prevention device,
ground fault circuit interrupter for electric shock prevention, crane collision prevention device, and energiz-
ing caution lamp, and check the following safety items.
• Observe the signals for sling work.
• Operate the hoist at a safe place.
• Be sure to check the directions of the direction indication plate (north, south, east and west) and the
operating button.
• Do not sling a load at an angle. Do not move the crane while the slung load is swinging.
• Do not raise or lower a load while the crane is moving longitudinally or laterally.
• Do not drag a sling.
• When lifting up a load, stop it just after it becomes off the ground, check the safety, and then lift it up.
• Consider the travel route in advance and lift up a load to a safe height.
• Place the control switch in a position where it is not an obstacle to work and passage.
• After operating the hoist, do not swing the control switch.
• Remember the position of the main switch so that you can turn off the power immediately in an emer-
gency.
• If the hoist stops because of a power failure, turn off the main switch. When turning on a switch after it
is turned off by the ground fault circuit interrupter, check that the devices related to that switch are not
in operating condition.
• If you find an obstacle around the hoist, stop the operation.
• After finishing the work, stop the hoist at the specified position and raise the hook to at least 2 m above
the floor. Do not leave the sling installed to the hook.
Selecting wire ropes
Select adequate ropes depending on the weight of the parts to be hoisted referring to the table below.
REMARK
The allowable load is calculated with one sixth (safety factor 6) of the breaking load of the rope.

Wire rope (JIS G3525 6x37-A type) (Standard Z twist wire ropes without galvanizing)
Nominal diameter of rope ( mm) Allowable load ( kN { t} )
10 8.8 {0.9}
12 12.7 {1.3}
14 17.3 {1.7}
16 22.6 {2.3}
18 28.6 {2.9}
20 35.3 {3.6}
25 55.3 {5.6}
30 79.6 {8.1}
40 141.6 {14.4}
50 221.6 {22.6}
60 318.3 {32.4}

00-24 PC45MR-5, PC55MR-5

00 INDEX AND FOREWORD SAFETY NOTICE FOR OPERATION

Precautions for disconnecting air conditioner piping

NOTICE
When replacing the air conditioner unit, air conditioner compressor, condenser or receiver drier, etc.,
collect the refrigerant (air conditioner gas: R134a) from the air conditioner circuit before disconnecting
the air conditioner hoses.
REMARK
• Ask a qualified person for collecting, adding and filling operations of the refrigerant (air conditioner gas:
R134a).
• Never release the refrigerant (air conditioner gas: R134a) to the atmosphere.
k Put on the protective eyeglasses, gloves and working clothes with long sleeves while you are col-
lecting or filling the refrigerant. Otherwise, when refrigerant gas (R134a) gets in your eyes, you may
lose your sight, and when it touches your skin, you may suffer from frostbite.
• When loosening the nuts fixing air conditioner hoses and tubes, be sure to use 2 wrenches; use one
wrench to fix and use the other one to loosen the nut.
Precautions for air conditioner piping
• When installing the air conditioner piping, be careful so that dirt, dusts and water do not enter the hose.
• Check that the O-rings are fitted to the joints when connecting the air conditioner piping.
• Do not reuse an O-ring because it is deformed and deteriorated if it is used once.
• When removing the O-rings, use a soft tool so that the piping is not damaged.
• Check that the O-ring is not damaged or deteriorated.
• Apply compressor oil for refrigerant (R134a) to O-ring.
REMARK
Do not apply oil to the threaded portion of a bolt, nut or union.
Manufacturer Part name
DENSO ND-OIL8
VALEO THERMAL SYSTEMS ZXL100PG (PAG46 or equivalent)
SANDEN SP-10

When tightening nuts of the air conditioner hoses and tubes, be sure to use 2 wrenches. Use one wrench to fix
and tighten the nut with the other wrench to the specified torque (Use a torque wrench for tightening).

PC45MR-5, PC55MR-5 00-25

SAFETY NOTICE FOR OPERATION 00 INDEX AND FOREWORD

REMARK
• The figure shows an example of fitting of O-ring.
• An O-ring is fitted to every joint of the air conditioner piping.
For tightening torques, see THE OTHER INFORMATION, "Pre-
cautions for disconnection and connection of air conditioner
piping".

00-26 PC45MR-5, PC55MR-5

00 INDEX AND FOREWORD PRECAUTIONS TO PREVENT FIRE

PRECAUTIONS TO PREVENT FIRE

Fire caused by fuel, oil, coolant or window washer fluid
Do not bring any open flame close to fuel, oil, coolant or win-
dow washer fluid. Always observe the following.
• Do not smoke or use any open flame near fuel or other
flammable substances.
• Shut down the engine before adding fuel.
• Do not leave the machine when adding fuel or oil.
• Tighten all the fuel and oil caps securely.
• Be careful not to spill fuel on overheated surfaces or on
,&
parts of the electrical system.
• After adding fuel or oil, wipe up any spilled fuel or oil.
• Put greasy rags and other flammable materials into a safe
container to maintain safety at the workplace.
• When washing parts with oil, use a non-flammable oil. Do
not use diesel oil or gasoline.There is danger that they
may catch fire.
• Do not weld or use a cutting torch to cut any pipes or tubes
that contain flammable liquids.
• Determine well-ventilated areas for storing oil and fuel. ,&
Keep the oil and fuel in the specified place and do not al-
low unauthorized persons to enter.
• When performing grinding or welding work on the machine, move any flammable materials to a safe place
before starting.
Fire caused by accumulation or attachment of flammable material
• Remove any dry leaves, chips, pieces of paper, coal dust, or any other flammable materials accumulated or
attached to or around the engine exhaust manifold, muffler, or battery, or on the undercovers.
• To prevent fires from being caught, remove any flammable materials such as dry leaves, chips, pieces of
paper, coal dust, or any other flammable materials accumulated around the cooling system (radiator, oil
cooler) or on the undercover.
Fire coming from electric wiring
Short circuits in the electrical system can cause fire. Always observe the following.
• Keep all the electric wiring connections clean and securely tightened.
• Check the wiring every day for looseness or damage. Reconnect any loose connectors or refasten wiring
clamps. Repair or replace any damaged wiring.
Fire caused by piping
Check that all the clamps for the hoses and tubes, guards, and cushions are securely fixed in position.
If they are loose, they may vibrate during operation and rub against other parts.There is danger that this may
lead to damage to the hoses and cause high-pressure oil to spurt out, leading to fire and serious personal injury
or death.
Fire around the machine due to highly heated exhaust gas
Some models and specifications may be equipped with KDPF (Komatsu Diesel Particulate Filter).
KDPF is a system for purifying exhaust gas by removing soot in exhaust gas. In the process of purification (re-
generation), the temperature of discharged exhaust gas may be higher than that of conventional models. Do not
bring any flammable materials close to exhaust pipe outlet.

PC45MR-5, PC55MR-5 00-27

PRECAUTIONS TO PREVENT FIRE 00 INDEX AND FOREWORD

• When there are thatched houses, dry leaves or pieces of paper near the work site, set the system to disa-
ble the regeneration before starting work to prevent fire hazards due to highly heated exhaust gas caused
by KDPF regeneration.
See the Operation and Maintenance Manual for the setting procedure.
Explosion caused by lighting equipment
• When checking fuel, oil, battery electrolyte, or coolant, always use lighting equipment with anti-explosion
specifications.
• When taking the electrical power for the lighting equipment from the machine, follow the instructions in the
Operation and Maintenance Manual.

00-28 PC45MR-5, PC55MR-5

00 INDEX AND FOREWORD ACTIONS IF FIRE OCCURS

ACTIONS IF FIRE OCCURS

• Turn the starting switch to OFF position to stop the engine.
• Use the handrails and steps to get off the machine.
• Do not jump off the machine. You may fall and suffer serious injury.
• The fumes generated by a fire contain harmful materials which have a bad influence on your body when
they are inhaled.
Do not breathe the fumes.
• After a fire, there may be harmful compounds left. If they touch your skin they may have a bad influence on
your body.
Be sure to wear rubber gloves when handling the materials left after the fire.
The material of the gloves, which is recommended is polychloroprene (Neoprene) or polyvinyl chloride (in
the lower temperature environment).
When wearing cotton work gloves, wear rubber gloves under them.

PC45MR-5, PC55MR-5 00-29

PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS 00 INDEX AND FOREWORD

PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS

To prevent pollution, pay full attention to the way to dispose of waste materials.
• Always drain the oil from your machine in containers. Nev-
er drain the oil and coolant directly onto the ground or
dump into the sewage system, rivers, seas, or lakes.
• Obey appropriate laws and regulations when disposing of
harmful objects such as oil, fuel, coolant, solvent, filters,
and batteries.

Avoid exposure to burning rubber or plastics which produce a toxic gas that is harmful to people.
• When disposing of parts made of rubber or plastics (hoses, cables, and harnesses), always comply with the
local regulations for disposing industrial waste products.

00-30 PC45MR-5, PC55MR-5

00 INDEX AND FOREWORD PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT

PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT

Because of the higher pressure and more precise hydraulic components, the most common cause of a failure is
dust (foreign material) in the hydraulic circuit. The special care must be taken when adding hydraulic oil, or
when disassembling, or assembling the hydraulic components.
Select an appropriate workplace
• In rain or high winds, or in dusty environment, avoid adding hydraulic oil, replacing filters, or repairing the
machine.
Disassembly and maintenance work in the field
k Any component may jump out or oil may spurt out by the remaining pressure in the hydraulic circuit
and it may result in serious personal injury or death when removing and disassembling of the hy-
draulic equipment is performed.
k Release the remaining pressure from the hydraulic circuit always before performing the work.

• In the field, there is a risk of dust entering the component

during disassembling or maintenance work, and perform-
ance check is hardly performed. Replacement of the as-
sembly is recommended.
• Perform disassembling and maintenance work in the dust
proof area.

Sealing of openings (prevention of flowing out of oil)

Plug the openings of the piping and the device which have been removed to prevent foreign material from enter-
ing and oil from flowing out.
NOTICE
Do not expose the openings or stuff it, otherwise foreign material may enter or leaked oil may pollute
the environment.
Do not discard the oil inconsiderately. Ask the customer for disposal or bring it back to dispose it ap-
propriately.
REMARK
Cover the places tightly with caps, tapes, or plastic bags if it is
hard to provide the plugs.

PC45MR-5, PC55MR-5 00-31

PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 00 INDEX AND FOREWORD

Preventing intrusion of foreign materials during refilling

• During refilling with the hydraulic oil, do not let water enter
the electrical components.
• Clean the oil filler port and its around, refilling pump, oil
jug, or etc.
• Refilling by using an oil cleaning device is better method
since it can filtrate the contaminants accumulated in the oil
during storage.

Replacing hydraulic oil while its temperature is high

• The higher the oil temperature is, the softer the oil is, and the smoother the oil runs. Also, the sludges are
easily discharged from the circuit. Perform the replacement while oil temperature is high.
• Old hydraulic oil needs to be drained as much as possible when replacing.
NOTICE
Old hydraulic oil contaminates the new one if it is mixed since it contains contaminants and sludg-
es, and the service life of the hydraulic oil is shortened.
REMARK
Drain the old hydraulic oil not only from the hydraulic tank but also from the filter and drain plug in the cir-
cuit.
Avoid reusing the hydraulic oil and lubricating oil
Avoid reusing the hydraulic oil and lubricating oil which has been drained from the machine.
If reused, any foreign material may enter the hydraulic equipment, and it may cause a failure.
Flushing operation
• Flushing is required to completely dislodge the contami-
nants and sludges, and existing oil containing those inside
the hydraulic circuit after disassembling and assembling,
and when replacing the oil with the new one.
• Normally, flushing is performed twice. Primary flushing is
performed by using the flushing oil (1) and the secondary
flushing is performed by using the specified hydraulic oil.

Cleaning operation
Perform oil cleaning to remove the contaminants and sludges in the hydraulic circuit after repair of the hydraulic
device (pump, or control valve) or during operation of the machine.

00-32 PC45MR-5, PC55MR-5

00 INDEX AND FOREWORD PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT

REMARK
The oil cleaning equipment can remove the ultra fine (approxi-
mately 3 μm) particles that the filter built in the hydraulic equip-
ment cannot remove. So, it is very effective device.

PC45MR-5, PC55MR-5 00-33

PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIP-
INGS 00 INDEX AND FOREWORD

PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS

When performing "testing and adjusting" of the machine, "removal and installation" and "disassembly and as-
sembly" of the components, observe the following precautions.
Precautions for removal and disassembling work
• If the cooling water contains coolant, dispose of it correctly as chemicals. Do not drain it to the sewage
rashly.
• After disconnecting the hoses or tubes, plug them to prevent dust from entering.
• When draining oil, prepare a container with sufficient capacity.
• Check the matchmarks which indicate the installing position, and put matchmarks on the places where they
seem necessary before removal of the components to prevent any mistake when assembling.
• To prevent any excessive force from being applied to the wiring, always hold the connectors when discon-
necting the connectors. Do not pull the wires.
• Attach the tags to wires and hoses so that installation is done to the correct installing positions.
• Check the thickness and number of shims when storing shims.
• When hoisting the components, prepare the slings with sufficient strength.
• When using forcing screws to remove any component, tighten the forcing screws uniformly and alternately.
• Before removing any component, clean the surrounding area and cover the component to prevent any for-
eign material from entering after removal.
• To disconnect the face seal type hose from the cylinder
tube, loosen the joint by gripping the two wrenches togeth-
er, one is the wrench (1) on the hose side, and another is
the wrench (2) on the cylinder tube reaction force point as
shown in the following figure. Use the grip strength on-
ly.Check after disconnecting the hose that the joint portion
of the cylinder and the cylinder tube is tightened to the
specified torque. Re-tighten it if the tightening torque is in-
sufficient.
NOTICE
Cylinder tube is rotated due to the load applied to the
reaction force point of the cylinder tube, and it is a
cause of weakening of the tightening torque. It may
lead to oil leakage.
• After disconnecting the piping or removing a pipe joint, install the following plugs.
NOTICE
When disassembling the machine, check the part number by referring to the Parts Book and use the
appropriate parts according to the usage conditions.
REMARK
The part numbers of O-ring shown in the table indicate the temporary part number when disassembling and
transporting the machine.

00-34 PC45MR-5, PC55MR-5

PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIP-
00 INDEX AND FOREWORD INGS

Introduction of parts for the disassembly of the face seal type hoses and tubes

Hose side Pipe joint side

Nominal No. O-ring (3)
Plug (1) Nut (2)
02 07376-70210 02789-00210 02896-11008
03 07376-70315 02789-00315 02896-11009
04 07376-70422 02789-00422 02896-11012
05 07376-70522 02789-00522 02896-11015
06 07376-70628 02789-00628 02896-11018

Introduction of parts for the disconnection of the taper seal type hoses and
tubes

Hose side Pipe joint side

Nominal No.
Plug (1) Nut (2)
02 07376-50210 07222-00210
03 07376-50315 07222-00312
04 07376-50422 07222-00414
05 07376-50522 07222-00515
06 07376-50628 07222-00616
10 07376-51034 07222-01018
12 07376-51234 07222-01219
14 07376-51443 07222-01422

PC45MR-5, PC55MR-5 00-35

PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIP-
INGS 00 INDEX AND FOREWORD

Introduction of parts for the disconnection of the split flange type hoses and
tubes

Nomi Bolt pitch (mm) Hose side Tube side

nal Split flange Sleeve head O-ring (4) Bolt (5) Washer (6)
No. a b Flange (1)
(2) (3)
04 38.1 17.5 07379-00400 07371-30400 07378-10400 07000-12021 01010-80825 01643-50823
05 42.9 19.8 07379-00500 07371-30500 07378-10500 07000-13022 01010-80830 01643-50823
06 47.6 22.2 07379-00640 07371-30640 07378-10600 07000-13025 07372-51035 01643-51032
10 52.4 26.2 07379-01044 07371-31049 07378-11000 07000-13032 07372-51035 01643-51032
58.7 30.2 07379-01250 07371-31255 07378-11200 07000-13038 07372-51035 01643-51032
12
66.7 31.8 07379-01260 07371-51260 07378-11210 07000-13038 01010-81245 01643-51232
69.9 35.8 07379-01460 07371-31465 07378-11400 07000-13048 07372-51240 01643-51232
14
79.4 36.5 07379-01470 07371-51470 07378-11410 07000-13048 01010-81455 01643-31445
77.8 42.8 07379-02071 07371-32076 07378-12000 07000-12060 07372-51240 01643-51232
20
96.8 44.5 07379-02080 07371-52080 07378-12010 07000-12060 01010-81865 01643-31845
24 88.9 50.8 07379-02484 07371-12484 07378-12400 07000-12070 07372-51240 01643-51232
30 106.4 62 07379-03010 07371-13010 07378-13000 07000-12085 07372-51650 01643-51645
34 120.6 69.8 07379-03411 07371-13411 07378-13400 07000-12100 07372-51650 01643-51645
40 130.2 77.8 07379-04012 07371-14012 07378-14000 07000-12110 07372-51650 01643-51645
50 152.4 92 07379-05011 07371-15011 07378-15000 07000-12135 07372-51655 01643-51645

Introduction of parts for the removal of O-ring boss type joint

00-36 PC45MR-5, PC55MR-5

PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIP-
00 INDEX AND FOREWORD INGS

Nominal No. Plug (1) O-ring (2)

08 07040-10807 07002-10823
10 07040-11007 07002-11023
12 07040-11209 07002-11223
14 07040-11409 07002-11423
16 07040-11612 07002-11623
18 07040-11812 07002-11823
20 07040-12012 07002-12034
24 07040-12412 07002-12434
30 07041-13012 07002-13034
33 07040-13316 07002-13334
36 07041-13612 07002-13634
42 07040-14220 07002-14234
52 07040-15223 07002-15234

Introduction of parts for the removal of taper pipe thread type joint

Nominal Plug (1)

Nominal No.
thread size Square head type (A) Hexagonal socket head (B)
01 R1/8 07042-00108 07043-00108

02 R1/4 07042-00211 07043-00211

03 R3/8 07042-00312 07043-00312

04 R1/2 07042-00415 07043-00415

06 R3/4 07042-00617 07043-00617

10 R1 07042-01019 07043-01019
12 R11/4 07042-01222 07043-01222

14 R11/2 07042-01422 07043-01422

20 R2 07042-02026 07043-02026

Precautions for installation and assembling work

• Tighten the bolts and nuts (sleeve nuts) to the specified torque (KES) unless otherwise specified.
• Install the hoses without twist and interference. If there is any in-between clamp, securely fasten it.

PC45MR-5, PC55MR-5 00-37

PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIP-
INGS 00 INDEX AND FOREWORD

• Replace all of the gaskets, O-rings, cotter pins, and lock plates with new ones.
• Bend the cotter pins and lock plates securely.
• When applying adhesive, clean and degrease the surface to apply, and apply 2 to 3 drops of adhesive to
the threaded portion.
• When applying liquid gasket, clean and degrease the surface, and apply it uniformly after making sure that
the surface is free from dust or damage.
• Clean all of the parts. If there is any damage, dents, burrs, or rust found on them, repair it.
• Apply engine oil to the rotating parts and sliding surface.
• Apply molybdenum disulfide lubricant (LM-P) to the surfaces of the press-fitting parts.
• After installing the snap ring, check that the snap ring is settled in the ring groove completely.
• When connecting wiring harness connectors, clean the connectors to remove oil, dust, or water, then con-
nect them securely.
• Use the eye bolts without fatigue and deformation and screw them in securely. Match the directions of the
eyes and the hook.
• When installing split flanges, tighten the bolts uniformly and alternately to prevent uneven tightening.
• As a rule, apply liquid gasket (LG-5) or liquid sealant (LS-2) to the threaded portion of each taper male
screws which receive pressure.
REMARK
If the threaded portion is difficult to degrease, you may use a seal tape.
When winding a seal tape onto a right-handed taper male screw, start winding the screw clockwise from the
third thread in the advancing direction of the threads seeing from the screw end.
NOTICE
If the seal tape is wound counterclockwise, it may become loose when screwed in, and it may come
off. If the sealed tip is pushed outside, it may cause oil leakage.
• To connect the face seal type hose to the cylinder tube,
tighten the joint by gripping the two wrenches together,
one is the wrench (1) on the hose side, and another is the
wrench (2) on the cylinder tube reaction force point at the
same time as shown in the following figure. Use the grip
strength only.Check after connecting the hose that the joint
portion of the cylinder and the cylinder tube is tightened to
the specified torque. Re-tighten it if the tightening torque is
insufficient.
NOTICE
Cylinder tube is rotated due to the load applied to the
reaction force point of the cylinder tube, and it is a
cause of weakening of the tightening torque. It may
lead to oil leakage.
NOTICE
When assembling the hydraulic equipment such as cylinders, pumps and pipings which are removed,
be sure to bleed air from the hydraulic circuit before operating it for the first time according to the fol-
lowing procedure.
1. Start the engine, and run it at low idle.
2. Perform the operation to extend and retract each cylinder of the work equipment and stop it at approximate-
ly 100 mm before the stroke end for 4 or 5 times.
3. Perform the operation to extend and retract each cylinder of the work equipment and stop it at the stroke
end for 3 or 4times.

00-38 PC45MR-5, PC55MR-5

PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIP-
00 INDEX AND FOREWORD INGS

NOTICE
After repair is finished, when operating the machine which has been stored for a long period, bleed air
from the hydraulic circuit according to the same procedure.
Precautions at the time of completion of work
Refilling of coolant or water or oil, greasing, and adding of AdBlue/DEF
• For machines with urea SCR system, fill AdBlue/DEF to the specified level before starting the engine.
• Supply the specified amount of grease to the work equipment parts.
• When the coolant is drained, be sure that the drain valve is securely tightened, then refill the coolant reser-
voir with the coolant Komatsu recommends to the specified level. Start the engine to circulate the coolant in
the piping, and add the coolant to the specified level again.
• When the hydraulic components are removed and installed, refill the tank with the oil Komatsu recommends
to the specified level. Start the engine to circulate the oil in the piping, and add the oil to the specified level
again.
• If the hydraulic piping or hydraulic equipment is removed, be sure to bleed air from the system after rebuild-
ing the parts, by referring to TESTING AND ADJUSTING.
Testing installed condition of cylinder heads and manifolds
• Check the cylinder head and intake and exhaust manifold mountings for looseness.
• If there is any looseness, retighten the part.
REMARK
For the tightening torques, see "DISASSEMBLY AND ASSEMBLY".
Test engine piping for damage and looseness
Intake and exhaust system
Check that there is no damage on the pipings, or no looseness on mounting bolts, nuts and clamps, or no leak
of air or exhaust gas from connecting portion.
If there is any looseness, damage, or gas leak, retighten or repair the part.
Cooling system
Check that there is no damage on the pipings, no looseness on mounting bolts, nuts and clamps, and no water
leak from connecting portion.
If there is any looseness, damage, or water leak, retighten or repair the part.
Fuel system
Check that there is no damage on the pipings, no looseness on mounting bolts, nuts and clamps, and no fuel
leak from connecting portion.
If there is any looseness, damage, or fuel leak, retighten or repair the part.
Check the exhaust equipment and its installation portion for looseness and damage.
REMARK
When an equipment is described as an exhaust equipment, it is one of the followings. (The applications or com-
ponents of equipment are different depending on its models or specifications.)
• KDPF
• AdBlue/DEF mixing tube
• SCR assembly
• KDOC muffler
• Muffler
• Exhaust pipe
• Parts which connects the above, or etc.
Visually check that there is no crack or no damage on the exhaust equipment and its installation portion. If there
is any damage, replace the part.

PC45MR-5, PC55MR-5 00-39

PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIP-
INGS 00 INDEX AND FOREWORD

Check that there is no looseness on the exhaust equipment and mounting bolts, nuts, and clamps on the instal-
lation portion.
If there is any looseness, retighten the part.
Check of function of muffler in exhaust system
REMARK
When an equipment is described as an muffler in exhaust system, it is one of the followings. (The applications
or components of equipment are different depending on its models or specifications.)
• KDPF
• AdBlue/DEF mixing tube
• SCR assembly
• KDOC muffler
• Muffler
• Exhaust pipe
• Parts which connects the above, or etc.
Check that there is no unusual noise by comparing to it of the time when the machine was new.
If there is any unusual noise, repair KDPF or muffler, referring to "TROUBLESHOOTING" and "DISASSEMBLY
AND ASSEMBLY".

00-40 PC45MR-5, PC55MR-5

00 INDEX AND FOREWORD PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT

PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT

To maintain the performance of the machine over a long period, and to prevent failures or troubles before they
occur, correct "operation", "maintenance and inspection" "troubleshooting", and "repairs" must be performed.
This section deals particularly with correct repair procedures for mechatronics components and is aimed at im-
proving the quality of repairs. For this purpose, it describes the working procedures in "Handling of electrical
equipment".
Handling wiring harnesses and connectors
• Wiring harnesses consist of wires connecting one compo-
nent to another component, connectors used for connect-
ing and disconnecting one wire from another wire, and pro-
tectors or tubes used for protecting the wires.
• Compared with other electrical components fitted in boxes
or cases, wiring harnesses are likely to be directly affected
by rain water, heat, or vibration. Furthermore, during in-
spection and repair operations, they are frequently re-
moved and installed again, so they are likely to suffer de-
formation or damage. For this reason, it is necessary to be
extremely careful when handling and maintenance of the
wiring harnesses.
• If AdBlue/DEF is spilled over wiring harness and connectors, it may cause corrosion and defective contact.
Be careful not to spill it over electrical equipment, wiring harness and connectors since AdBlue/DEF is
strongly corrosive to metal.
Main causes of failure in wiring harness
Defective contact of connectors (defective contact between male and female connectors)
Problems with defective contact are likely to occur because the
male connector is not properly inserted into the female connec-
tor,or because one or both of connectors are deformed or the
position is not correctly aligned, or because there is corrosion
or oxidization of the contact surfaces. The corroded or oxidized
contact surfaces may become shiny again (and contact may
become normal) by connecting and disconnecting the connec-
tors approximately 10 times.

Defective crimping or soldering of connectors

The pins of the male and female connectors are attached to
wires by crimping or soldering. If excessive force is applied to
the wire, the jointed portion (1) may become loose, and it may
result in a defective connection or breakage.

PC45MR-5, PC55MR-5 00-41

PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT 00 INDEX AND FOREWORD

Disconnection in wiring
If the wiring harness is pulled to disconnect the connector, or
the components are lifted with a crane while the wiring harness
is still connected, or a heavy object hits the wiring harness, it
may separate the crimping of the connector, or damage the sol-
dering, or break the wiring harness.

Water entering the connector by high-pressure jetting

The connector is designed to make it difficult for water to enter
(drip-proof structure), but if high-pressure water is sprayed di-
rectly on the connector, water may enter the connector, de-
pending on the direction of the water jet.
Do not spray water directly on the connector.
If the connector is waterproof, intruded water is hardly drained.
Once water enters into the connector, water goes through pins
to cause short-circuit. Drying the drenched connector or take
appropriate actions before providing electricity.
Entry of water, dirt, or dust when disconnecting a con-
nector
If any water, mud or dust is stuck to the outside surface of a connector, it can enter inside the connector when
the connector is disconnected. Before disconnecting the connector, wipe off any stuck water or dirt by using a
dry cloth or blow it with compressed air.
Oil, mud, or dust stuck to connector
If any oil or grease is stuck to the connector and an oil film is
formed on the mating surface of the male and female pins, the
oil prevents electricity from passing through resulting in defec-
tive contact. If any oil, grease, dirt or dust is stuck to the con-
nector, wipe it off with a dry cloth or blow it with compressed air,
and wash it with electrical contact restorer.
NOTICE
• When wiping the jointed portion of the connector, do
not apply excessive force or deform the pins.
• If there is oil or water in the compressed air, it causes
the contacts to become dirtier. Use clean air which any
oil and water has been removed from.

00-42 PC45MR-5, PC55MR-5

00 INDEX AND FOREWORD PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT

PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT

The machines equipped with common rail fuel injection system (CRI) consists of more precise parts than the
parts used in the conventional fuel injection pump and nozzle. If foreign material enters this system, it may
cause a failure. Use special care to prevent entry of the foreign material when servicing the fuel system.
Select an appropriate workplace
Avoid the work of adding hydraulic oil, replacing filters, or repairing the machine in rainy or windy weather, or in
dusty environment.
Sealing the opening
Plug the removed pipes and the openings of the removed components with the caps, tapes, plastic bags, etc. to
prevent foreign material from entering.
NOTICE
Do not expose the openings or stuff it, otherwise foreign
material may enter or leaked oil may pollute the environ-
ment.
Do not discard the oil inconsiderately. Ask the customer
for disposal or bring it back to dispose it appropriately.

How to clean parts when dirt is stuck

If any dirt or dust sticks the parts of the fuel system, clean it off thoroughly with clean fuel.
Precautions for replacing fuel filter cartridge
Be sure to use the Komatsu genuine fuel filter cartridge.
NOTICE
The machine equipped with common rail fuel injection system (CRI) consists of more precise parts than
the parts used in the conventional fuel injection pump and nozzle. In order to prevent foreign material
from entering this system, the filter employs a specially high performance of filter element. If a filter oth-
er than a Komatsu genuine filter is used, fuel system contamination and damage may occur. Therefore
Komatsu recommends using only Komatsu fuel filters and install them following the procedures in the
shop manual.

PC45MR-5, PC55MR-5 00-43

PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT 00 INDEX AND FOREWORD

PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT

The machines equipped with Variable Geometry Turbocharger (VGT) consists of more precise parts (variable
system)than the parts used in the conventional turbocharger. If foreign material enters this system, it may cause
a failure. Use special care to prevent entry of the foreign material when servicing the intake system.
Select an appropriate workplace
Avoid the work of adding hydraulic oil, replacing filters, or repairing the machine in rainy or windy weather, or in
dusty environment.
Sealing the opening
Plug the removed pipes and the openings of the removed components with the caps, tapes, plastic bags, etc. to
prevent foreign material from entering.
NOTICE
Do not expose the openings or stuff it, otherwise foreign material may enter it.

00-44 PC45MR-5, PC55MR-5

00 INDEX AND FOREWORD PRACTICAL USE OF KOMTRAX

PRACTICAL USE OF KOMTRAX

Various information which KOMTRAX system transmits by using the radio communication is useful for KOM-
TRAX operator to provide various services for the customers.
When KOMTRAX system is installed to the machine and it is enabled, machine information can be checked by
KOMTRAX system, and it is used for testing and troubleshooting to be performed efficiently.
Large-sized models are equipped with KOMTRAX Plus which can use more detailed information.
REMARK
(KOMTRAX may not be installed to the machine in some countries or areas.)
Merit of using KOMTRAX
• The location where the machine is working at can be checked on the map in a personal computer.
• Operation information such as service meter, operating hours, fuel consumption, and occurred caution as
well as failure code can be checked.
• The operator can check the hours used and replacement interval of consumable parts of the machine such
as fuel filter, hydraulic oil filter, hydraulic oil and engine oil.
• Information of how machine is operated (idling time, traveling time, digging time, relieving time, etc.) can be
checked, and it is used to presume the machine operating condition.
• Various reports such as “Fuel saving operation support”, “Operation summary”, etc. is generated, and it is
utilized as an advice tool for the user and operator.
• KOMTRAX Plus can record the data of abnormality record, trend data, snap shot data, etc. to grasp the
soundness of machine, in addition to KOMTRAX function described above. These data can be used on per-
sonal computer screens.
How to make a full use of KOMTRAX
Making use of KOMTRAX enables the following activities.
• Quick response to a request for immediate repair
1. To check the displayed caution and failure code, etc. through KOMTRAX upon receiving a repair re-
quest from a user.
2. To immediately arrange necessary tools, replacement parts, etc, immediately in accordance with the
displayed failure code.
3. To find the location of the failed machine by using the map of KOMTRAX, to visit the customer there.
• Proactive maintenance
1. To check the service summary screen of KOMTRAX, to find the machine which has high priority failure
code indicated by a red or yellow flag.
2. To check the condition of the machine with the customer and to make a plan to visit.
3. To immediately arrange necessary tools, replacement parts, etc, immediately in accordance with the
displayed failure code.
• Practice of periodic maintenance and periodic inspection service
1. To check the service summary screen of KOMTRAX, and to find the machine of which the usage limits
for the consumable parts indicated by red flags are over.
2. To submit an estimate sheet for the consumable parts to be replaced and the labor cost for the replace-
ment work to the customer.
3. To propose the periodic inspection (Pm clinic, etc.) according to the service meter reading.
How to operate KOMTRAX
For the operating method of each screen of KOMTRAX, ask KOMTRAX key person in your Komatsu distributor.

PC45MR-5, PC55MR-5 00-45

DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER 00 INDEX AND FOREWORD

DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER

REMARK
• Loosen the oil filler cap of the hydraulic tank slowly to release the remaining pressure in the hydraulic tank.
• Provide an oil container to receive oil since some hydraulic oil flows out when the hose is disconnected even
after the remaining pressure is released from the hydraulic tank.

METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE

COUPLER
Disconnection
1. Hold adapter (1), and push hose joint (2) into mating
adapter (3).
REMARK
• Push it in approximately 3.5 mm.
• Do not hold rubber cap portion (4).

2. While having adapter (3) inserted into hose side joint (2),
insert rubber cap (4) to adapter (3) side until it clicks.

3. Hold hose adapter (1) or hose (5), and pull it out.

REMARK
Provide an oil container to receive a quantity of hydraulic
oil which may flow out.

Connection
1. Hold hose adapter (1) or hose (5), and insert it in mating
adapter (3), aligning the axis.
REMARK
Do not hold rubber cap portion (4).

00-46 PC45MR-5, PC55MR-5

00 INDEX AND FOREWORD DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER

2. After inserting the hose in the mating adapter perfectly, pull

it back to check the connecting condition.
REMARK
When the hose fitting is pulled back, the rubber cap moves
approximately 3.5 mm toward the hose, but it is not a prob-
lem.

METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE

COUPLER
Disconnection
1. Hold the tightening adapter part and push body (2) straight
until sliding prevention ring (1) contacts contact surface (a)
of the hexagonal part at the male end.

2. While keeping the condition of step 1, turn lever (3) to the

right (clockwise).

3. While keeping the conditions of steps 1 and 2, pull out

whole body (2) to disconnect it.
REMARK
Provide an container to receive a quantity of hydraulic oil
which may flow out.

PC45MR-5, PC55MR-5 00-47

DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER 00 INDEX AND FOREWORD

Connection
Hold the tightening adapter part, and push body (2) straight un-
til sliding prevention ring (1) contacts contact surface (a) of the
hexagonal part at the male end.

METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE

COUPLER
Disconnection
1. Hold the tightening adapter part and push body (2) straight
until sliding prevention ring (1) contacts contact surface (a)
of the hexagonal part at the male end.

2. While keeping the condition of step 1, push cover (3)

straight until it contacts contact surface (a) of the hexago-
nal portion on the male side.

3. While keeping the conditions of steps 1 and 2, pull out

whole body (2) to disconnect it.
REMARK
Provide an container to receive a quantity of hydraulic oil
which may flow out.

00-48 PC45MR-5, PC55MR-5

00 INDEX AND FOREWORD DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER

Connection
Hold the tightening adapter part, and push body (2) straight un-
til sliding prevention ring (1) contacts contact surface (a) of the
hexagonal part at the male end.

PC45MR-5, PC55MR-5 00-49

PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CON-
NECTORS 00 INDEX AND FOREWORD

PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNEC-

TORS
Disconnecting connectors
1. Hold the connectors when disconnecting.
When disconnecting the connectors, always hold the con-
necting portion. If the connector is fixed with screw, loosen
the screw of the connector completely, hold the both of
male and female connectors, and pull them out in parallel.
NOTICE
Do not pull the connectors with one hand.
REMARK
If it is a lock stopper type connector, pull it out as pushing
the stopper (1) with your thumb.
2. When removing a connector from a clip
• Both of the connector and clip have stoppers (2),
which are engaged with each other when the connec-
tor is connected.
• When removing a connector from a clip, pull the con-
nector in parallel with the clip as removing stoppers.
NOTICE
If the connector is pried up and down or to the
right or left, it may break the housing.

3. Action to be taken after removing connectors

After removing the connector, cover it with plastic bags to
prevent entry of dust, dirt, oil, or water in the contact por-
tion.
NOTICE
Be sure to cover the connector with plastic bags when
leaving the machine disassembled for a long time, oth-
erwise defective contact may occur.

Connecting connectors
1. Check the connector visually.
• Check that there is no dust, dirt, oil, or water stuck to the connector pins (joint portion).

00-50 PC45MR-5, PC55MR-5

PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CON-
00 INDEX AND FOREWORD NECTORS

• Check that there is no deformation, defective contact, corrosion, or damage on the connector pins.
• Check that there is no damage or crack on the external surfaces of the connectors.
NOTICE
• If there is any dust, dirt, oil, or water stuck to the connector, wipe it off with a dry cloth. If there is
any water intrusion into the connector, warm the inside of the connector and harness with a dry-
er. Do not overheat the connector, otherwise short circuit may occur.
• If there is any damage or breakage, replace the connector.
2. Connecting the connector securely
Position connector (1) correctly, and fit it in securely.
REMARK
If the connector is lock stopper type, insert it until it clicks.
3. Correct the protrusion of the boot and misalignment of the
wiring harness.

• If the connector is with the boot, correct any extrusion of the boot. In addition, if the wiring harness is
misaligned or the clamp is out of position, adjust it to its correct position.
REMARK
If the protrusion of the boot and misalignment of the
wiring harness cannot be fixed, remove the clamp to
adjust them.

• If the connector clamp is removed, be sure to return it

to its original position. Check that there is no loose-
ness.

Drying wiring harness

REMARK
If the wiring harness is dirty with oil and dust, wipe it off with a dry cloth. Avoid water washing or steam washing.
If water washing is unavoidable, do not use high-pressure water or steam directly on the wiring harness. If water
gets directly on the connector, do as follows.

PC45MR-5, PC55MR-5 00-51

PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CON-
NECTORS 00 INDEX AND FOREWORD

1. Disconnect the connector and wipe off the water with a dry
cloth.
NOTICE
If the connector is to be blown with dry compressed
air, there is the risk that oil in the air may cause defec-
tive contact, remove oil and water in the air before
starting air blow.

2. Dry the inside of the connector with a dryer.

If water enters inside the connector, use a dryer to dry the
connector.
NOTICE
Hot air from a dryer can be used, but limit the time of
using a dryer to prevent the connector or related parts
from becoming too hot, as this will cause deformation
or damage to the connector.

3. Perform a continuity test on the connector.

After drying, leave the wiring harness disconnected, con-
nect T-adapter(1), and perform a continuity test to check
for any short circuits between pins caused by water or etc.
REMARK
After the connector is completely dried, blow the contact
restorer, and reassemble them.

Handling controller
k When performing arc welding on the machine body, disconnect all of the wiring harness connectors
connected to the controller. Fit an arc welding ground close to the welding point.

00-52 PC45MR-5, PC55MR-5

PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CON-
00 INDEX AND FOREWORD NECTORS

NOTICE
• Controller has been assembled with electronic circuits
for control including microcomputers. These electronic
circuits inside of the controller must be handled with
care since they control the machine.
• Do not leave things on the controller.
• Cover the connector portion of the controller with a
tape and a plastic bag. Do not touch the connecting
portion of connector.
• Do not leave the controller in a place where it is ex-
posed to rain.
• Do not place the controller on oil, water, soil or any pla-
ces where the temperature is likely to be high even for
a short period of time (Place it on a suitable dry stand).

Precautions for troubleshooting electrical circuits

• Be sure to turn the starting switch to OFF position before disconnecting or connecting the connectors.
• Before performing troubleshooting, check all the related connectors for loose connection.
REMARK
Check the related connectors for their performance by disconnecting and connecting them several times.
• Be sure to connect all the disconnected connectors before proceeding to the next step.
NOTICE
If the starting switch is turned to ON position while the connectors are disconnected, an unrelated
failure beside the actual failed part may be displayed.
• When performing the troubleshooting for the circuit (measurement of voltage, resistance,continuity, current,
etc.), shake the related wiring harnesses and connectors several times and check that the multimeter read-
ing does not change.
NOTICE
If the value changes on the multimeter, there may be a defective contact in the circuit.

PC45MR-5, PC55MR-5 00-53

METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH
CONNECTOR 00 INDEX AND FOREWORD

METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNEC-

TOR
Method for disconnecting Deutsch connector
While pressing locks (a) and (b) from each side respectively,
pull out female connector (2).

Method for connecting Deutsch connector

1. Push in female connector (2) horizontally, and insert it
straight until it clicks. (Arrow: x)
2. In order to check whether locks (a) and (b) are completely
inserted, insert female connector (2) by rocking it vertically
(in the arrow z direction). (Arrow: x, y, z)
REMARK
Lock (a) in the figure is pulled down (not set completely),
and lock (b) is set completely.

00-54 PC45MR-5, PC55MR-5

METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK
00 INDEX AND FOREWORD TYPE CONNECTOR

METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE

CONNECTOR
Method for disconnecting slide lock type connector (FRAMATOME-3, FRAMA-
TOME-2)
1. Slide lock (L1) to the right.
2. While pressing lock (L2), pull out connector (1) toward you.
REMARK
If portion A does not float when lock (L2) is pressed, and if
connector (1) does not come out when it is pulled toward
you, push up portion A with a small flat-head screwdriver
while pressing lock (L2), and then pull out connector (1) to-
ward you.

Method for connecting slide lock type connector (FRAMATOME-3, FRAMA-

TOME-2)
Insert it straight until it clicks.

Method for disconnecting slide lock type connector (FRAMATOME-24)

1. Slide down lock (red) (L1).

PC45MR-5, PC55MR-5 00-55

METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK
TYPE CONNECTOR 00 INDEX AND FOREWORD

2. While pressing lock (L2), pull out connector (1).

REMARK
Lock (L2) is located behind connector (1) in the figure.

Method for connecting slide lock type connector (FRAMATOME-24)

Insert it straight until it clicks.

00-56 PC45MR-5, PC55MR-5

METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR
00 INDEX AND FOREWORD WITH LOCK TO PULL

METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH

LOCK TO PULL
Method for disconnecting connector with lock to pull
Disconnect the connector (2) by pulling lock (B) (on the wiring
harness side) of connector (2) outward.

Method for connecting connector with lock to pull

Insert the connector securely until it "clicks".

PC45MR-5, PC55MR-5 00-57

METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR
WITH LOCK TO PUSH 00 INDEX AND FOREWORD

METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH

LOCK TO PUSH
Method for disconnecting connector with lock to push (BOSCH-3)
While pressing lock (C), pull out connector (3) in the direction of the arrow.
• 114 series

• 107 series

REMARK
If the lock is located on the underside, use flat-head screwdriver [1] since you cannot insert your fingers.
While pushing up lock (C) of the connector with flat-head
screwdriver [1], pull out connector (3) in the direction of the ar-
row.

Method for connecting connector with lock to push (BOSCH-3)

Insert it straight until it clicks.

00-58 PC45MR-5, PC55MR-5

METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR
00 INDEX AND FOREWORD WITH LOCK TO PUSH

Method for disconnecting connector with lock to push (AMP-3)

While pressing lock (E), pull out connector (5) in the direction of
the arrow.

Method for connecting connector with lock to push (AMP-3)

Insert it straight until it clicks.

Method for disconnecting connector with lock to push (SUMITOMO-3)

While pressing lock (E), pull out connector (5) in the direction of
the arrow.
REMARK
Pull up the connector straight.

Method for connecting connector with lock to push (SUMITOMO-3)

Insert it straight until it clicks.

Method for disconnecting connector with lock to push (SUMITOMO-4)

While pressing lock (D), pull out connector (4) in the direction
of the arrow.

Method for connecting connector with lock to push (SUMITOMO-4)

Insert it straight until it clicks.

PC45MR-5, PC55MR-5 00-59

METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR
WITH HOUSING TO ROTATE 00 INDEX AND FOREWORD

METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH

HOUSING TO ROTATE
Method for disconnecting connector with housing to rotate
Turn housing (H1) to the left, and pull it out.
REMARK
Housing (H1) is left on the wiring harness side.

Method for connecting connector with housing to rotate

1. Insert the connector to the end while aligning its groove to the other.
2. Turn housing (H1) clockwise until it clicks.

00-60 PC45MR-5, PC55MR-5

00 INDEX AND FOREWORD HOW TO READ ELECTRICAL WIRE CODE

HOW TO READ ELECTRICAL WIRE CODE

In the electrical circuit diagram, the material, thickness, and color of each electric wire are indicated by symbols.
The electrical wire code is helpful in understanding the electrical circuit diagram.
Example) AEX 0.85 L: Indicates heat-resistant, low-voltage blue wire for automobile, having nominal No. of 0.85
Indicates type of wire by symbol.
Type, symbol, and material of wire are shown in (Table 1).
AEX
(Since the use of AV and AVS wires depends on size (nominal No.), the symbols are not indicated on
the diagram.)
Indicates size of wire by nominal No.
0.85
Sizes (Nominal Nos.) are shown in (Table 2).
Indicates color of wire by color code.
L
Color codes are shown in (Table 3).

Type, symbol, and material

AV and AVS are different in only thickness and outside diameter of the coating. CAVS has a circular com-
pressed conductor. It differs from AV and AVS in the outside diameter of conductor and thickness of the coating.
AEX is similar to AV in thickness and outside diameter of the coating but different from AV and AVS in material
of the coating.
(Table 1)
Temperature
Sym- Conductor ma-
Type Insulator material range (°C) in Example of use
bol terial
use
Low-voltage For large current wiring
wire for auto- AV
mobile (nominal No. 5 and above)

Thin-cover
low-voltage
General wiring
wire for auto- AVS
mobile (nominal No. 3 and lower)
Soft polyvinyl chloride -30 to +60
(Type 1)
Annealed cop-
Thin-cover per for electric
low-voltage appliance For mid- to small-size excava-
wire for auto- CAVS tors
mobile (nominal No. 1.25 and lower)
(Type 2)

Heat-resistant General wiring for extremely

low-voltage Heat-resistant cross- cold weather specification
AEX -50 to +110
wire for auto- linked polyethylene Wiring at high-temperature
mobile place

PC45MR-5, PC55MR-5 00-61

HOW TO READ ELECTRICAL WIRE CODE 00 INDEX AND FOREWORD

Dimensions

(Table 2)
Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5
Number of
20 7 30 11 50 16 37 26 58 41 65
strands
Diameter of
0.18 0.32 0.18 0.32 0.18 0.32 0.26 0.32 0.26 0.32 0.32
strand
Conductor
Cross-sec-
tional area 0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23
( mm2)
d (approx.) 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0
AVS Standard 2.0 2.2 2.5 2.9 2.9 3.5 3.6 -
Coating D

AV Standard - - - - - - - 4.6
AEX Standard 2.0 2.2 2.7 3.0 3.1 - 3.8 4.6

Nominal No. 8 15 20 30 40 50 60 85 100

Number of
50 84 41 70 85 108 127 169 217
strands
Diameter of
0.45 0.45 0.80 0.80 0.80 0.80 0.80 0.80 0.80
strand
Conductor
Cross-sec-
tional area 7.95 13.36 20.61 35.19 42.73 54.29 63.84 84.96 109.1
( mm2)
d (approx.) 3.7 4.8 6.0 8.0 8.6 9.8 10.4 12.0 13.6
AVS Standard - - - - - - - - -
Coating D

AV Standard 5.5 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
AEX Standard 5.3 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6

Nominal No. 0.5f 0.5 0.75f 0.85 1.25f 1.25

Number of
- 7 - 11 - 16
strands
Diameter of round compres- round compres-
- - round compression
strand sion sion
Conductor
Cross-sec-
tional area - 0.56 - 0.88 - 1.29
( mm2)
d (approx.) - 0.9 - 1.1 - 1.4

00-62 PC45MR-5, PC55MR-5

00 INDEX AND FOREWORD HOW TO READ ELECTRICAL WIRE CODE

Nominal No. 0.5f 0.5 0.75f 0.85 1.25f 1.25

Coating D

CAVS Standard - 1.6 - 1.8 - 2.1

REMARK
“f” of nominal No. denotes "flexible".
Color codes table
(Table 3)
Color Code Color of wire Color Code Color of wire
B Black LgW Light green and White
Br Brown LgY Light green and Yellow
BrB Brown and Black LR Blue and Red
BrR Brown and Red LW Blue and White
BrW Brown and White LY Blue and Yellow
BrY Brown and Yellow O Orange
Ch Charcoal P Pink
Dg Dark green R Red
G Green RB Red and Black
GB Green and Black RG Red and Green
GL Green and Blue RL Red and Blue
Gr Gray RW Red and White
GR Green and Red RY Red and Yellow
GW Green and White Sb Sky Blue
GY Green and Yellow Y Yellow
L Blue YB Yellow and Black
LB Blue and Black YG Yellow and Green
Lg Light green YL Yellow and Blue
LgB Light green and Black YR Yellow and Red
LgR Light green and Red YW Yellow and White

REMARK
In a color code consisting of 2 colors, the first color is the color of the background and the second color is the
color of the marking.
Example) GW indicates that the background is "Green" and marking is "White".

PC45MR-5, PC55MR-5 00-63

HOW TO READ ELECTRICAL WIRE CODE 00 INDEX AND FOREWORD

Types of circuits and color codes

Type of wire AVS, AV, CAVS AEX
Charge R WG - - - - R -
Ground B - - - - - B -
Start R - - - - - R -
Light RW RB RY RG RL - O -
Instrument Y YR YB YG YL YW Y Gr
Signal G GW GR GY GB GL G Br
L LW LR LY LB - L -
Type of circuit Br BrW BrR BrY BrB - - -
Lg LgR LgY LgB LgW - - -
O - - - - - - -
Others Gr - - - - - - -
P - - - - - - -
Sb - - - - - - -
Dg - - - - - - -
Ch - - - - - - -

00-64 PC45MR-5, PC55MR-5

00 INDEX AND FOREWORD EXPLANATION OF TERMS FOR MAINTENANCE STANDARD

EXPLANATION OF TERMS FOR MAINTENANCE STANDARD

The maintenance standard section shows the judgment criteria whether the equipment or parts should be re-
placed or can be reused when the machine is disassembled for the maintenance. The following terms are the
descriptions of the judgment criteria.
Standard dimension and tolerance
• The finished dimension of a part is slightly different from one to another actually.
• A standard dimension of a finished part is set, and an allowable difference from that dimension is set for the
part.
• The dimension set as the standard is called the standard dimension and the allowable range of difference
from this standard dimension is called "tolerance".
• An indication example of a standard dimension and tolerance is shown in the following table.
(The standard dimension is entered on the left side and the tolerance is entered with a positive or negative
symbol on the right side)
Example:
Standard dimension Tolerance
-0.022
120
-0.126

• The tolerance may be indicated in the text and a table as "standard dimension (upper limit of tolerance/
lower limit of tolerance)."
Example) 120 (-0.022/ -0.126)
• Usually, the dimension of a hole and the dimension of the shaft to be inserted into that hole are indicated by
the same standard dimension and different tolerances of the hole and shaft. The tightness of fit is deter-
mined by the tolerance.
• A dimension indication example of a shaft and hole is shown in the following table.
(The standard dimension is entered on the left side and the tolerance of the shaft is entered with a positive
or negative symbol at the center and that of the hole on the right side)
Tolerance
Standard dimension
Shaft Hole
-0.030 +0.046
60
-0.076 0

PC45MR-5, PC55MR-5 00-65

EXPLANATION OF TERMS FOR MAINTENANCE STANDARD 00 INDEX AND FOREWORD

Standard clearance and standard value

• The clearance made when new parts are assembled is
called the standard clearance, which is indicated by the
range from the minimum clearance to the maximum clear-
ance.
• When some parts are repaired, the clearance is generally
adjusted to the standard clearance.
• The values indicating performance and function of new
products or equivalent are called "standard value", which is
indicated by a range or a target value.
• When some parts are repaired, the value of performance/
function is set to the standard value.

Standard interference
• When the diameter of a hole of a part shown in the given standard dimension and tolerance table is smaller
than that of the shaft to be inserted, the difference between those diameters is called "interference".
• Subtract the maximum dimension of the hole from the minimum dimension of the shaft and call it (A). Sub-
tract the minimum dimension of the hole from the maximum dimension of the shaft and call it (B). The range
between (A) and (B) is "standard interference".
• After repairing or replacing some parts, measure the dimension of their hole and shaft and check that the
interference is in the standard range.
Repair limit and allowable value or allowable dimension
• The dimension of parts changes due to the wear or deformation while they are used. When the dimension
changes exceeding certain value, parts cannot be used any longer. This value is called "repair limit".
• If a part is worn to the repair limit, it must be replaced or repaired.
• The performance and function of products lower while they are used. A value with which the product can be
used without causing a problem is called "allowable value" or "allowable dimension".
• A product whose dimension is out of the allowable value, must be repaired. However, since the allowable
values are generally estimated through various tests or experiences in most cases, the judgment must be
made in consideration of the operating condition and customer's requirement.
Allowable clearance
• Parts can be used until the clearance between them is increased to a certain limit. The limit at which those
parts cannot be used is called "allowable clearance".
• If the clearance between the parts exceeds the allowable clearance, they must be replaced or repaired.
Allowable interference
• The allowable maximum interference between the hole of a part and the shaft of another part to be assem-
bled is called "allowable interference".
• The allowable interference shows the repair limit of the part of smaller tolerance.

00-66 PC45MR-5, PC55MR-5

00 INDEX AND FOREWORD EXPLANATION OF TERMS FOR MAINTENANCE STANDARD

• The parts whose interferences are out of the allowable interference must be replaced or repaired.

PC45MR-5, PC55MR-5 00-67

STANDARD TIGHTENING TORQUE TABLE 00 INDEX AND FOREWORD

STANDARD TIGHTENING TORQUE TABLE

Table of tightening torque for bolts and nuts
REMARK
Tighten the metric nuts and bolts to the torque shown in the table below unless otherwise specified.

Thread diameter Width across flats

Tightening torque ( Nm { kgm} )
( mm) ( mm)
10
6 11.8 to 14.7 {1.2 to 1.5}
(*2) 10
13
8 27 to 34 {2.8 to 3.5}
(*2) 12
17
10 59 to 74 {6 to 7.5}
(*1, *2) 14
19
12 98 to 123 {10 to 12.5}
(*1, *2) 17
14 22 153 to 190 {15.5 to 19.5}
24
16 235 to 285 {23.5 to 29.5}
(*1) 22
18 27 320 to 400 {33 to 41}
20 30 455 to 565 {46.5 to 58}
22 32 610 to 765 {62.5 to 78}
24 36 785 to 980 {80 to 100}
27 41 1150 to 1440 {118 to 147}
30 46 1520 to 1910 {155 to 195}
33 50 1960 to 2450 {200 to 250}
36 55 2450 to 3040 {250 to 310}
39 60 2890 to 3630 {295 to 370}

*1: Split flange bolt

*2: Flanged bolt
REMARK
Tighten the flanged bolt marked with “7” on the head as shown in the following to the tightening torque shown in
the table below.

00-68 PC45MR-5, PC55MR-5

00 INDEX AND FOREWORD STANDARD TIGHTENING TORQUE TABLE

Thread diameter Width across flats

Tightening torque ( Nm { kgm} )
( mm) ( mm)
6 10 5.9 to 9.8 {0.6 to 1.0}
8 12 13.7 to 23.5 {1.4 to 2.4}
10 14 34.3 to 46.1 {3.5 to 4.7}
12 17 74.5 to 90.2 {7.6 to 9.2}

REMARK
Tighten the unified coarse threaded bolts and nuts to the torque shown in the table below unless otherwise
specified.

Type of bolt A B

Nominal size - Tightening torque ( Nm { kgm} ) Tightening torque ( Nm { kgm} )

threads per inch Range Target Range Target
1/ 9.8 to 14.7 {1 to 1.5} 12.7 {1.3} 2.9 to 3.9 {0.3 to 0.4} 3.43 {0.35}
4-20UNC

5/ 24.5 to 34.3 {2.5 to 3.5} 29.4 {3} 6.9 to 8.8 {0.7 to 0.9} 7.8 {0.8}
16-18UNC

3/ 44.1 to 58.8 {4.5 to 6} 52.0 {5.3} 9.8 to 14.7 {1 to 1.5} 11.8 {1.2}
8-16UNC

7/ 73.5 to 98.1 {7.5 to 10} 86.3 {8.8} 19.6 to 24.5 {2 to 2.5} 21.6 {2.2}
16-14UNC

1/ 108 to 147 {11 to 15} 127 {13} 29.4 to 39.2 {3 to 4} 34.3 {3.5}
2-13UNC

9/ 157 to 216 {16 to 22} 186 {19} 44.1 to 58.8 {4.5 to 6} 51.0 {5.2}
16-12UNC

5/ 226 to 294 {23 to 30} 265 {27} 63.7 to 83.4 {6.5 to 8.5} 68.6 {7}
8-11UNC

3/ -10UNC 392 to 530 {40 to 54} 461 {47} 108 to 147 {11 to 15} 127 {13}
4

7/ 637 to 853 {65 to 87} 745 {76} 177 to 235 {18 to 24} 206 {21}
8-9UNC

PC45MR-5, PC55MR-5 00-69

STANDARD TIGHTENING TORQUE TABLE 00 INDEX AND FOREWORD

Type of bolt A B

Nominal size - Tightening torque ( Nm { kgm} ) Tightening torque ( Nm { kgm} )

threads per inch Range Target Range Target
1-8UNC 883 to 1196 {90 to 122} 1040 {106} 245 to 333 {25 to 34} 284 {29}

11/8-7UNC 1187 to 1608 {121 to 164} 1393 {142} 333 to 451 {34 to 46} 392 {40}

11/4-7UNC 1598 to 2157 {163 to 220} 1873 {191} 451 to 608 {46 to 62} 530 {54}

11/2-6UNC 2354 to 3177 {240 to 324} 2765 {282} 657 to 892 {67 to 91} 775 {79}

REMARK
Tighten the unified fine threaded bolts and nuts to the torque shown in the table below unless otherwise speci-
fied.

Type of bolt A B

Nominal size - Tightening torque ( Nm { kgm} ) Tightening torque ( Nm { kgm} )

threads per inch Range Target Range Target
1/ 14.7 to 19.6 {1.5 to 2} 17.7 {1.8} 3.9 to 4.9 {0.4 to 0.5} 4.41 {0.45}
4-28UNF

5/ 34.3 to 39.2 {3.5 to 4} 34.3 {3.5} 7.8 to 9.8 {0.8 to 1} 8.8 {0.9}
16-24UNF

3/ 53.9 to 68.6 {5.5 to 7} 61.8 {6.3} 14.7 to 19.6 {1.5 to 2} 16.7 {1.7}
8-24UNF

7/ 83.4 to 108 {8.5 to 11} 96.1 {9.8} 24.5 to 29.4 {2.5 to 3} 26.5 {2.7}
16-20UNF

1/ 127 to 167 {13 to 17} 147 {15} 34.3 to 49.0 {3.5 to 5} 41.2 {4.2}
2-20UNF

9/ 186 to 245 {19 to 25} 216 {22} 49.0 to 68.6 {5 to 7} 58.8 {6}
16-18UNF

5/ 255 to 343 {26 to 35} 294 {30} 73.5 to 98.1 {7.5 to 10} 83.4 {8.5}
8-18UNF

3/ 441 to 598 {45 to 61} 520 {53} 127 to 167 {13 to 17} 147 {15}
4-16UNF

7/ 716 to 961 {73 to 98} 843 {86} 196 to 265 {20 to 27} 226 {23}
8-14UNF

1-14UNF 1020 to 1373 {104 to 140} 1196 {122} 284 to 382 {29 to 39} 333 {34}

11/8-12UNF 1353 to 1844 {138 to 188} 1598 {163} 382 to 520 {39 to 53} 451 {46}

11/4-12UNF 1804 to 2432 {184 to 248} 2118 {216} 510 to 686 {52 to 70} 598 {61}

11/2-12UNF 2707 to 3658 {276 to 373} 3177 {324} 765 to 1030 {78 to 105} 892 {91}

00-70 PC45MR-5, PC55MR-5

00 INDEX AND FOREWORD STANDARD TIGHTENING TORQUE TABLE

Table of tightening torque for O-ring boss piping joints

REMARK
Tighten the pipe joint for O-ring boss to the torque shown in the table below unless otherwise specified.

Thread di- Tightening torque ( Nm { kgm} )

Width across
Nominal No. ameter
flats ( mm) Range Target
( mm)
02 14 35 to 63 {3.5 to 6.5} 44 {4.5}
- 18 59 to 98 {6.0 to 10.0} 78 {8.0}
Varies de-
03, 04 20 pending on 84 to 132 {8.5 to 13.5} 103 {10.5}
05, 06 24 type of con- 128 to 186 {13.0 to 19.0} 157 {16.0}
nector.
10, 12 33 363 to 480 {37.0 to 49.0} 422 {43.0}
14 42 746 to 1010 {76.0 to 103} 883 {90.0}

Table of tightening torque for O-ring boss plugs

REMARK
Tighten the plug for O-ring boss to the torque shown in the table below unless otherwise specified.

Thread diam- Width across Tightening torque ( Nm { kgm} )

Nominal No.
eter ( mm) flats ( mm) Range Target
08 8 14 5.88 to 8.82 {0.6 to 0.9} 7.35 {0.75}
10 10 17 9.8 to 12.74 {1.0 to 1.3} 11.27 {1.15}
12 12 19 14.7 to 19.6 {1.5 to 2.0} 17.64 {1.8}
14 14 22 19.6 to 24.5 {2.0 to 2.5} 22.54 {2.3}
16 16 24 24.5 to 34.3 {2.5 to 3.5} 29.4 {3.0}

PC45MR-5, PC55MR-5 00-71

STANDARD TIGHTENING TORQUE TABLE 00 INDEX AND FOREWORD

Thread diam- Width across Tightening torque ( Nm { kgm} )

Nominal No.
eter ( mm) flats ( mm) Range Target
18 18 27 34.3 to 44.1 {3.5 to 4.5} 39.2 {4.0}
20 20 30 44.1 to 53.9 {4.5 to 5.5} 49.0 {5.0}
24 24 32 58.8 to 78.4 {6.0 to 8.0} 68.6 {7.0}
30 30 32 93.1 to 122.5 {9.5 to 12.5} 107.8 {11.0}
33 33 - 107.8 to 147.0 {11.0 to 15.0} 127.4 {13.0}
36 36 36 127.4 to 176.4 {13.0 to 18.0} 151.9 {15.5}
42 42 - 181.3 to 240.1 {18.5 to 24.5} 210.7 {21.5}
52 52 - 274.4 to 367.5 {28.0 to 37.5} 323.4 {33.0}

Table of tightening torque for hose (taper seal type and face seal type)
REMARK
• Tighten the hose fittings (taper seal type and face seal type) to the torque shown in the following table un-
less otherwise specified.
• The table is applied to the threaded portion coated with engine oil (wet threaded portion).

Width Tightening torque ( Nm { kgm} ) Taper seal Face seal

Nominal
across Nominal size - Thread root
No. of Thread size
flats Range Target threads per diameter( mm)
hose ( mm)
( mm) inch (reference)
34 to 54 {3.5 to 5.5} 44 {4.5} - 9/ 14.3
16-18UN
02 19
34 to 63 {3.5 to 6.5} 44 {4.5} 14 - -
22 54 to 93 {5.5 to 9.5} 74 {7.5} - 11/ -16UN 17.5
16
03
24 59 to 98 {6.0 to 10.0} 78 {8.0} 18 - -
04 27 84 to 132 {8.5 to 13.5} 103 {10.5} 22 13/ -16UN 20.6
16

05 32 128 to 186 {13.0 to 19.0} 157 {16.0} 24 1 -14UNS 25.4

06 36 177 to 245 {18.0 to 25.0} 216 {22.0} 30 13/16-12UN 30.2
(10) 41 177 to 245 {18.0 to 25.0} 216 {22.0} 33 - -
(12) 46 197 to 294 {20.0 to 30.0} 245 {25.0} 36 - -
(14) 55 246 to 343 {25.0 to 35.0} 294 {30.0} 42 - -

00-72 PC45MR-5, PC55MR-5

00 INDEX AND FOREWORD STANDARD TIGHTENING TORQUE TABLE

Table of tightening torque for face seal joints

REMARK
• The tightening torque table below applies to the seal joint (sleeve nut type) made with steel pipe for plated
low pressure piping which is used for engine.
• The table is applied to the threaded portion coated with engine oil (wet threaded portion).
• Reference: The face seal joint of the dimension in ( ) is also used depending on the specification.

Outside di- Tightening torque ( Nm { kgm} ) Face seal

Width
ameter of Thread root diam-
across flats Nominal size -
adequate Range Target eter( mm) (refer-
( mm) threads per inch
pipe ( mm) ence)
8 19 14 to 16 {1.4 to 1.6} 15 {1.5} 9/ 14.3
16-18UN

10 22 24 to 27 {2.4 to 2.7} 25.5 {2.6} 11/ -16UN 17.5

12 24 (27) 43 to 47 {4.4 to 4.8} 45 {4.6} 13/ 20.6

16-16UN

15 (16) 30 (32) 60 to 68 {6.1 to 6.8} 64 {6.5} 1 -14UNS 25.4

22 (20) 36 90 to 95 {9.2 to 9.7} 92.5 {9.4} 13/16-12UN 30.2

Tightening torque table for bolts and nuts on 102,107 and 114 series engines
REMARK
Tighten the metric threads bolts and nuts used on the 102, 107 and 114 series engines to the torques shown in
the following table unless otherwise specified.
Thread diameter ( mm) Tightening torque ( Nm { kgm} )
6 10±2 {1.02±0.20}
8 24±4 {2.45±0.41}
10 43±6 {4.38±0.61}
12 77±12 {7.85±1.22}
14 -

Tightening torque table for 102, 107, and 114 series engines (joint bolts)
REMARK
Tighten the metric joint bolts used on the 102, 107, and 114 series engines to the torque shown in the following
table unless otherwise specified.

PC45MR-5, PC55MR-5 00-73

STANDARD TIGHTENING TORQUE TABLE 00 INDEX AND FOREWORD

Thread diameter ( mm) Tightening torque ( Nm { kgm} )

6 8±2 {0.81±0.20}
8 10±2 {1.02±0.20}
10 12±2 {1.22±0.20}
12 24±4 {2.45±0.41}
14 36±5 {3.67±0.51}

Tightening torque table for tapered screws on 102,107, and 114 series engines
(National taper pipe thread (NPT))
REMARK
Tighten the National taper pipe threaded (NPT) screws used on the 102, 107, and 114 series engines to the
torques shown in the following table unless otherwise specified.
Material of female screw In cast iron or steel In aluminum
Nominal thread size Tightening torque ( Nm { kgm} ) Tightening torque ( Nm { kgm} )
1/ 15±2 {1.53±0.20} 5±1 {0.51±0.10}
16

1/ 20±2 {2.04±0.20} 15±2 {1.53±0.20}

1/ 25±3 {2.55±0.31} 20±2 {2.04±0.20}

3/ 35±4 {3.57±0.41} 25±3 {2.55±0.31}

1/ 55±6 {5.61±0.61} 35±4 {3.57±0.41}

3/ 75±8 {7.65±0.82} 45±5 {4.59±0.51}

00-74 PC45MR-5, PC55MR-5

00 INDEX AND FOREWORD CONVERSION TABLE

CONVERSION TABLE
Method of using the conversion table
The conversion table is provided to enable simple conversion of the numerical numbers between the different
units. For further details of the method of using the conversion table, see the examples given below.
Examples of using the conversion table to convert a unit from mm to in.
When converting 55 mm to in
1. Locate the number 50 in the leftmost column, take this as (A), and then draw a horizontal line from (A).
2. Locate the number 5 in the top row, take this as (B), then draw a vertical line down from (B).
3. Take the crossover point of the two lines as (C). This point (C) gives the value when converting the unit
from mm to in. Accordingly, 55 mm = 2.165 in.
When converting 550 mm to in
1. The number 550 does not appear in the table. Divide it by 10 (move the decimal point one place to the left)
to get 55 mm.
2. Convert 55 mm to 2.165 in according to the preceding procedure.
3. The original value (550 mm) has been divided by 10, so multiply 2.165 in by 10 (move the decimal point
one place to the right) to restore the target value. This gives 550 mm = 21.65 in
mm to in
(B)
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
(C)
50 1.969 2.008 2.017 2.087 2.126 2.165 2.205 2.244 2.283 2.323
(A)
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.847 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.780 3.819 3.858 3.898

mm to in
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323

PC45MR-5, PC55MR-5 00-75

CONVERSION TABLE 00 INDEX AND FOREWORD

1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.847 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898

kg to lb
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26

ℓ to U.S.Gal
1 ℓ = 0.2642 U.S.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378
10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153

ℓ to U.K.Gal
1 ℓ = 0.21997 U.K.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379

00-76 PC45MR-5, PC55MR-5

00 INDEX AND FOREWORD CONVERSION TABLE

1 ℓ = 0.21997 U.K.Gal
0 1 2 3 4 5 6 7 8 9
30 6.599 6.819 7.039 7.259 7.479 7.699 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777

kgm to lbft
1 kgm = 7.233 lbft
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4

kg/cm2 to lb/in2
1 kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7

PC45MR-5, PC55MR-5 00-77

CONVERSION TABLE 00 INDEX AND FOREWORD

1 kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408
100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 1863 1877 1892 1906 1920 1934 1949 1963 1977
140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119
150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688
190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830
200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542

Temperature
Conversion of Fahrenheit to Celsius
• A simple way to convert a Fahrenheit temperature reading into a Celsius temperature reading or vice versa
is to see the number in the center column of the following table. The figures in the center of the following
table show the temperatures in both Fahrenheit and Celsius.
• When converting from Fahrenheit to Celsius degrees, consider the center column to be a table of Fahren-
heit temperatures and read the corresponding Celsius temperature in the column at the left.
• When converting from Celsius to Fahrenheit degrees, consider the center column to be a table of Celsius
values, and read the corresponding Fahrenheit temperature on the right.
1 °C = 33.8 °F
°C °F °C °F °C °F °C °F
-40.4 -40 -40.0 -11.7 11 51.8 7.8 46 114.8 27.2 81 177.8
-37.2 -35 -31.0 -11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
-34.4 -30 -22.0 -10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
-31.7 -25 -13.0 -10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
-28.9 -20 -4.0 -9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
-28.3 -19 -2.2 -8.9 16 60.8 10.6 51 123.8 30.0 86 186.8
-27.8 -18 -0.4 -8.3 17 62.6 11.1 52 125.6 30.6 87 188.6

00-78 PC45MR-5, PC55MR-5

00 INDEX AND FOREWORD CONVERSION TABLE

1 °C = 33.8 °F
°C °F °C °F °C °F °C °F
-27.2 -17 1.4 -7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
-26.7 -16 3.2 -7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
-26.1 -15 5.0 -6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
-25.6 -14 6.8 -6.1 21 69.8 13.3 56 132.8 32.8 91 195.8
-25.0 -13 8.6 -5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
-24.4 -12 10.4 -5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
-23.9 -11 12.2 -4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
-23.3 -10 14.0 -3.9 25 77.0 15.6 60 140.0 35.0 95 203.0
-22.8 -9 15.8 -3.3 26 78.8 16.1 61 141.8 35.6 96 204.8
-22.2 -8 17.6 -2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
-21.7 -7 19.4 -2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
-21.1 -6 21.2 -1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
-20.6 -5 23.0 -1.1 30 86.0 18.3 65 149.0 37.8 100 212.0
-20.0 -4 24.8 -0.6 31 87.8 18.9 66 150.8 40.6 105 221.0
-19.4 -3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
-18.9 -2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
-18.3 -1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
-17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
-17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0
-16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
-16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
-15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
-15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
-14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0
-13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
-13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
-12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
-12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0

PC45MR-5, PC55MR-5 00-79

01 SPECIFICATIONS

S/T
Steering
STRG
SIG Signal
SOL Solenoid
STD Standard
OPT
Option
OP
PRESS Pressure
SPEC Specification
SW Switch
TEMP Temperature
T/C Torque Converter
T/M Transmission

01-8 PC45MR-5, PC55MR-5

01 SPECIFICATIONS SPECIFICATION DRAWING

SPECIFICATIONS
SPECIFICATION DRAWING
SPECIFICATION DRAWING: PC45MR-5

PC45MR-5
Item Unit
Canopy specification Cab specification
Machine weight
Rubber shoe specification kg 4790 4910
Steel shoe specification 4860 4930
Bucket capacity m3 0.14
Engine model - Komatsu 4D88E-7 diesel engine
Engine rated horsepower
kW
• Gross (SAE J1995) { HP} / 29.1 {39.0}/ 2400 {2400}
• ISO 14396 min-1 29.1 {39.0}/ 2400 {2400}
{ rpm}
• Net (ISO 9249/SAE J1349) 28.3 {38.0}/ 2400 {2400}
A Overall length mm 5330
B Overall height mm 2550 2590
C Overall width mm 1960
D Shoe width mm 400
E Tail swing radius mm 1040
F Overall length of the track mm 2520
G Distance between tumbler centers mm 2000
Minimum ground clearance mm 290
Travel speed (Lo/Hi)
Rubber shoe specification km/h 2.6/4.6
Steel shoe specification 2.4/4.3
min-1
Continuous swing speed 9.0 {9.0}
{ rpm}

PC45MR-5, PC55MR-5 01-9

SPECIFICATION DRAWING 01 SPECIFICATIONS

REMARK
The engine rated horsepower is indicated in the net value and gross value. Gross denotes the rated horsepower
measured on the basic engine unit while net denotes the value measured of an engine under the condition near-
ly the same as that when it is installed on a machine.

01-10 PC45MR-5, PC55MR-5

01 SPECIFICATIONS SPECIFICATION DRAWING

SPECIFICATION DRAWING: PC55MR-5

PC55MR-5
Item Unit
Canopy specification Cab specification
Machine weight
Rubber shoe specification kg 5070 5190
Steel shoe specification 5140 5260
Bucket capacity m3 0.16
Engine model - Komatsu 4D88E-7 diesel engine
Engine rated horsepower
kW
• Gross (SAE J1995) { HP} / 29.1 {39.0}/ 2400 {2400}
• ISO 14396 min-1 29.1 {39.0}/ 2400 {2400}
{ rpm}
• Net (ISO 9249/SAE J1349) 28.3 {38.0}/ 2400 {2400}
A Overall length mm 5550
B Overall height mm 2550 2590
C Overall width mm 1960
D Shoe width mm 400
E Tail swing radius mm 1120
F Overall length of the track mm 2520
G Distance between tumbler centers mm 2000
Minimum ground clearance mm 290
Travel speed (Lo/Hi)
Rubber shoe specification km/h 2.6/4.6
Steel shoe specification 2.4/4.3
min-1
Continuous swing speed 9.0 {9.0}
{ rpm}

PC45MR-5, PC55MR-5 01-11

SPECIFICATION DRAWING 01 SPECIFICATIONS

REMARK
• The engine rated horsepower is indicated in the net value and gross value. Gross denotes the rated horse-
power measured on the basic engine unit while net denotes the value measured of an engine under the con-
dition nearly the same as that when it is installed on a machine.

01-12 PC45MR-5, PC55MR-5

01 SPECIFICATIONS WORKING RANGE DRAWINGS

WORKING RANGE DRAWINGS

WORKING RANGE: PC45MR-5

Item Unit PC45MR-5

A Maximum digging reach mm 6040
B Maximum digging depth mm 3625
C Maximum digging height mm 5730
D Maximum vertical wall digging depth mm 3070
E Maximum dumping height mm 4000
Minimum swing radius of work equipment 2380
F mm
Minimum turning radius during boom swing 1840
G Maximum reach at ground level mm 5895
H Maximum raising distance of the blade mm 430
I Maximum lowering distance of the blade mm 330

PC45MR-5, PC55MR-5 01-13

WORKING RANGE DRAWINGS 01 SPECIFICATIONS

WORKING RANGE: PC55MR-5

Item Unit PC55MR-5

A Maximum digging reach mm 6220
B Maximum digging depth mm 3770
C Maximum digging height mm 5915
D Maximum vertical wall digging depth mm 3030
E Maximum dumping height mm 4200
Minimum swing radius of work equipment 2285
F mm
Minimum turning radius during boom swing 1760
G Maximum reach at ground level mm 6075
H Maximum raising distance of the blade mm 430
I Maximum lowering distance of the blade mm 330

*1: Values shown in ( ) are dimensions in boom swing operation.

01-14 PC45MR-5, PC55MR-5

01 SPECIFICATIONS SPECIFICATIONS

SPECIFICATIONS
SPECIFICATIONS: PC45MR-5
PC45MR-5
Item Unit
Canopy specifications Cab specifications
Bucket capacity m3 0.14
Machine weight
Rubber shoe specification kg 4790 4910
Steel shoe specification 4860 4930

Performance
Working ranges
Maximum digging depth mm 3625
Maximum vertical wall digging
mm 3070
depth
Maximum digging reach mm 6040
Maximum digging reach at
mm 5895
ground level
Maximum digging height mm 5730
Maximum dumping height mm 4000
Offset of bucket (Left side/right
mm 630/880
side)
Maximum raising distance of
mm 430
the blade
Maximum lowering distance of
mm 330
the blade
Maximum digging force kN { kg} 33.9 {3460} 33.9 {3460}
Continuous swing speed min-1 { rpm} 9.0 {9.0} 9.0 {9.0}
Swing operation max. slope angle Degrees 19.0 19.0
Travel speed (Lo/Hi)
Rubber shoe specification km/h 2.6/4.6 2.6/4.6
Steel shoe specification 2.4/4.3 2.4/4.3
Gradeability Degrees 30 30
Ground pressure
Rubber shoe specification kPa { kg/cm2} 27.4 {0.28} 28.0 {0.29}
Steel shoe specification 27.8 {0.28} 28.4 {0.29}

Dimensions
Overall length (for transport) mm 5330 5330
Overall width mm 1960 1960
Overall height (for transport) mm 2550 2590
Ground clearance of upper struc-
mm 608 608
ture bottom
Minimum ground clearance mm 290 290

PC45MR-5, PC55MR-5 01-15

SPECIFICATIONS 01 SPECIFICATIONS

PC45MR-5
Item Unit
Canopy specifications Cab specifications
Tail swing radius mm 1040 1040
Minimum swing radius of work
2380 2380
equipment
mm
Minimum turning radius during
1840 1840
boom swing
Maximum height at minimum swing
mm 4140 4140
radius of work equipment
Overall width of track mm 1960 1960
Overall length of the track mm 2520 2520
Distance between tumbler centers mm 2000 2000
Distance between track centers mm 1560 1560
Machine cab height mm 1395 1395
Blade width x height mm 1960 x 355 1960 x 355

Engine
Model - 4D88E-7
Type - 4-stroke, water-cooled, in-line vertical, direct injection type
No. of cylinders - bore x stroke mm 4-88 x 90
Total piston displacement ℓ { cc} 2.189 {2189}
Performance
Rated horsepower
• SAE J1995 (gross) 29.1 {39.0}/ 2400 {2400}
kW
• ISO 14396 29.1 {39.0}/ 2400 {2400}
{ HP} / min-1
• ISO 9249/SAE J1349 { rpm}
28.3 {38.0}/ 2400 {2400}
(net)
Nm
Maximum torque { kgm} / min-1 137.3 {14.0}/ 1560 {1560}
{ rpm}
Fuel consumption ratio at rated g/kWh
232 {173}
horsepower { g/HPh}
Maximum speed with no load min-1 { rpm} 2550 {2550}
Minimum speed with no load min-1 { rpm} 1225 {1225}
Starting motor
• Serial No.: 4814 to 21759 – 12 V, 2.3 kW
• Serial No.: 21453 and up – 12 V, 1.7 kW
Alternator - 12 V, 40 A 12 V, 55 A
Battery (*1) - 12 V, 72 Ah x 1 pieces 12 V, 72 Ah x 1 pieces
Radiator core type - V-shaped fin

01-16 PC45MR-5, PC55MR-5

01 SPECIFICATIONS SPECIFICATIONS

PC45MR-5
Item Unit
Canopy specifications Cab specifications
*1: The battery capacity (Ah) is indicated in the 5-hour rate.
REMARK
The engine rated horsepower is indicated in the net value and gross value. Gross denotes the rated horsepower
measured on the basic engine unit while net denotes the value measured of an engine under the condition nearly
the same as that when it is installed on a machine.
Undercarriage
Carrier roller - 1 pieces on one side
Track roller - 4 pieces on one side
Track shoe -
Steel shoe - Assembly type triple grouser shoe, 39 pieces on each side
Rubber shoe - Rubber track

Hydraulic system
Main pump -
Type x quantity - Variable displacement piston type x 1piece
Theoretical discharged volume cm3/rev 22.3
Set pressure MPa { kg/cm2} 26.5 {270}
Swing and blade pump -
Type x quantity - Gear type x 1 piece
Theoretical discharged volume cm3/rev 14.1
Set pressure MPa { kg/cm2} 21.6{220}
Pilot pump -
Type x quantity - Gear type x 1 piece
Theoretical discharged volume cm3/rev 5.2
Set pressure MPa { kg/cm2} 3.14{32}
Control valve
Type x quantity - 8-spool type x 1 piece
Operating method - Hydraulic assist type
Travel motor
Variable displacement piston type x 2 pieces
Type x quantity -
(With counterbalance valve, travel shaft brake)
Swing motor
Fixed displacement piston type x 1 piece
Type x quantity -
(With brake valve, swing shaft brake)
Boom cylinder
Type - Double-acting piston type
Cylinder bore mm 90
Piston rod diameter mm 55
Stroke mm 691
Max. distance between pins mm 1739

PC45MR-5, PC55MR-5 01-17

SPECIFICATIONS 01 SPECIFICATIONS

PC45MR-5
Item Unit
Canopy specifications Cab specifications
Min. distance between pins mm 1048
Arm cylinder
Type - Double-acting piston type
Cylinder bore mm 80
Piston rod diameter mm 50
Stroke mm 649
Max. distance between pins mm 1631
Min. distance between pins mm 981.5
Bucket cylinder
Type - Double-acting piston type
Cylinder bore mm 70
Piston rod diameter mm 45
Stroke mm 580
Max. distance between pins mm 1480
Min. distance between pins mm 900
Boom swing cylinder
Type - Double-acting piston type
Cylinder bore mm 90
Piston rod diameter mm 50
Stroke mm 630
Max. distance between pins mm 1573.5
Min. distance between pins mm 943.5
Blade cylinder
Type - Double-acting piston type
Cylinder bore mm 110
Piston rod diameter mm 50
Stroke mm 140
Max. distance between pins mm 642.5
Min. distance between pins mm 502.5
Hydraulic tank - Box-shaped open type
Hydraulic oil filter - Tank return side
Hydraulic oil cooler - Air-cooled (V-fin)

01-18 PC45MR-5, PC55MR-5

01 SPECIFICATIONS SPECIFICATIONS

SPECIFICATIONS: PC55MR-5
PC55MR-5
Item Unit
Canopy specifications Cab specifications
Bucket capacity m3 0.16
Machine weight
Rubber shoe specification kg 5070 5190
Steel shoe specification 5140 5260

Performance
Working ranges
Maximum digging depth mm 3770
Maximum vertical wall digging
mm 3030
depth
Maximum digging reach mm 6220
Maximum digging reach at
mm 6075
ground level
Maximum digging height mm 5915
Maximum dumping height mm 4200
Offset of bucket (Left side/right
mm 630/880
side)
Maximum raising distance of
mm 430
the blade
Maximum lowering distance of
mm 330
the blade
Maximum digging force kN { kg} 39.0 {3980} 39.0 {3980}
min-1
Continuous swing speed 9.0 {9.0} 9.0 {9.0}
{ rpm}
Swing operation max. slope angle Degrees 19.0 19.0
Travel speed (Lo/Hi)
Rubber shoe specification km/h 2.6/4.6 2.6/4.6
Steel shoe specification 2.4/4.3 2.4/4.3
Gradeability Degrees 30 30
Ground pressure
kPa
Rubber shoe specification 28.9 {0.29} 29.6 {0.30}
{ kg/cm2}
Steel shoe specification 29.3 {0.30} 30.0 {0.31}

Dimensions
Overall length (for transport) mm 5550 5550
Overall width mm 1960 1960
Overall height (for transport) mm 2550 2590
Ground clearance of upper struc-
mm 608 608
ture bottom
Minimum ground clearance mm 290 290
Tail swing radius mm 1120 1120

PC45MR-5, PC55MR-5 01-19

SPECIFICATIONS 01 SPECIFICATIONS

PC55MR-5
Item Unit
Canopy specifications Cab specifications
Minimum swing radius of work
2285 2285
equipment
mm
Minimum turning radius during
1760 1760
boom swing
Maximum height at minimum
mm 4475 4475
swing radius of work equipment
Overall width of track mm 1960 1960
Overall length of the track mm 2520 2520
Distance between tumbler centers mm 2000 2000
Distance between track centers mm 1560 1560
Machine cab height mm 1395 1395
Blade width x height mm 1960 x 355 1960 x 355

Engine
Model - 4D88E-7
Type - 4-stroke, water-cooled, in-line vertical, direct injection type
No. of cylinders - bore x stroke mm 4-88 x 90
Total piston displacement ℓ { cc} 2.189 {2189}
Performance
Rated horsepower
• SAE J1995 (gross) 29.1 {39.0}/ 2400 {2400}
kW
• ISO 14396 { HP} / 29.1 {39.0}/ 2400 {2400}
min-1
• ISO 9249/SAE J1349
{ rpm} 28.3 {38.0}/ 2400 {2400}
(net)
Nm
{ kgm} /
Maximum torque 137.3 {14.0}/ 1560 {1560}
min-1
{ rpm}
Fuel consumption ratio at rated g/kWh
232 {173}
horsepower { g/HPh}
min-1
Maximum speed with no load 2550 {2550}
{ rpm}
min-1
Minimum speed with no load 1225 {1225}
{ rpm}
Starting motor
• Serial No.: 4814 to 21759 – 12 V, 2.3 kW
• Serial No.: 21453 and up – 12 V, 1.7 kW
Alternator - 12 V, 40 A 12 V, 55 A
Battery (*1) - 12 V, 72 Ah x 1 piece 12 V, 72 Ah x 1 piece
Radiator core type - V-shaped fin

01-20 PC45MR-5, PC55MR-5

01 SPECIFICATIONS SPECIFICATIONS

PC55MR-5
Item Unit
Canopy specifications Cab specifications
*1: The battery capacity (Ah) is indicated in the 5-hour rate.
REMARK
The engine rated horsepower is indicated in the net value and gross value. Gross denotes the rated horsepower
measured on the basic engine unit while net denotes the value measured of an engine under the condition nearly
the same as that when it is installed on a machine.
Undercarriage
Carrier roller - 1 pieces on one side
Track roller - 4 pieces on one side
Track shoe -
Steel shoe - Assembly type triple grouser shoe, 39 pieces on each side
Rubber shoe - Rubber track

Hydraulic system
Main pump -
Type x quantity - Variable displacement piston type x 1 piece
Theoretical discharged volume cm3/rev 22.3
MPa
Set pressure 26.5 {270}
{ kg/cm2}
Swing and blade pump -
Type x quantity - Gear type x 1 piece
Theoretical discharged volume cm3/rev 14.1
MPa
Set pressure 21.6{220}
{ kg/cm2}
Pilot pump -
Type x quantity - Gear type x 1 piece
Theoretical discharged volume cm3/rev 5.2
MPa
Set pressure 3.14{32}
{ kg/cm2}
Control valve
Type x quantity - 8-spool type x 1 piece
Operating method - Hydraulic assist type
Travel motor
Variable displacement piston type x 2 pieces
Type x quantity -
(With counterbalance valve, travel shaft brake)
Swing motor
Fixed displacement piston type x 1 piece
Type x quantity -
(With brake valve, swing shaft brake)
Boom cylinder
Type - Double-acting piston type
Cylinder bore mm 90
Piston rod diameter mm 55

PC45MR-5, PC55MR-5 01-21

SPECIFICATIONS 01 SPECIFICATIONS

PC55MR-5
Item Unit
Canopy specifications Cab specifications
Stroke mm 691
Max. distance between pins mm 1739
Min. distance between pins mm 1048
Arm cylinder
Type - Double-acting piston type
Cylinder bore mm 85
Piston rod diameter mm 55
Stroke mm 733
Max. distance between pins mm 1821
Min. distance between pins mm 1088
Bucket cylinder
Type - Double-acting piston type
Cylinder bore mm 75
Piston rod diameter mm 50
Stroke mm 580
Max. distance between pins mm 1480
Min. distance between pins mm 900
Boom swing cylinder
Type - Double-acting piston type
Cylinder bore mm 95
Piston rod diameter mm 50
Stroke mm 630
Max. distance between pins mm 1573.5
Min. distance between pins mm 943.5
Blade cylinder
Type - Double-acting piston type
Cylinder bore mm 110
Piston rod diameter mm 50
Stroke mm 140
Max. distance between pins mm 642.5
Min. distance between pins mm 502.5
Hydraulic tank - Box-shaped open type
Hydraulic oil filter - Tank return side
Hydraulic oil cooler - Air-cooled (V-fin)

01-22 PC45MR-5, PC55MR-5

01 SPECIFICATIONS WEIGHT TABLE

WEIGHT TABLE
WEIGHT TABLE: PC45MR-5
k This weight table is provided for your reference when handling the components or when transport-
ing.
k This weight table shows the dry weight.
Unit: kg
Item PC45MR-5
Engine assembly 265
• Engine 217
• Engine mount 8
• PTO 10
• Main pump 29
Cooling assembly 32
Battery 24
Revolving frame 529
Floor frame assembly (*1) 163
Canopy (*1) 114
Handrail (*1) 6
Operator's cab assembly (including floor frame assembly) (*2) 426
Operator's seat 25
Fuel tank 6
Hydraulic tank 40
Control valve 50
Counterweight 622
Swing motor (including brake valve) 15
Swing circle 59
Swing machinery 26
Center swivel joint 18
Track frame assembly (excluding track shoes) 944
• Track frame 551
• Idler assembly 36 x 2
• Recoil spring assembly 18 x 2
• Carrier roller 3x2
• Track roller 10 x 8
• Travel motor (including reduction gear) 49 x 2
• Sprocket 12 x 2
Track shoe assembly
Rubber shoe (400 mm) 242 x 2
Road liner (400 mm) 269 x 2
Triple grouser shoe (400 mm) 274 x 2

PC45MR-5, PC55MR-5 01-23

WEIGHT TABLE 01 SPECIFICATIONS

Unit: kg
Item PC45MR-5
Boom swing bracket assembly 101
Boom assembly 161
Arm assembly 94
Bucket link assembly 28
Bucket assembly (including side cutter) 101
Blade assembly 210
Boom cylinder assembly 46
Arm cylinder assembly 35
Bucket cylinder assembly 25
Boom swing cylinder assembly 35
Blade cylinder assembly 29
*1: Canopy specification
*2: Cab specification

01-24 PC45MR-5, PC55MR-5

01 SPECIFICATIONS WEIGHT TABLE

WEIGHT TABLE: PC55MR-5

k This weight table is provided for your reference when handling the components or when transport-
ing.
k This weight table shows the dry weight.
Unit: kg
Item PC55MR-5
Engine assembly 265
• Engine 217
• Engine mount 8
• PTO 10
• Main pump 29
Cooling assembly 32
Battery 24
Revolving frame 529
Floor frame assembly (*1) 163
Canopy (*1) 114
Handrail (*1) 6
Operator's cab assembly (including floor frame assembly) (*2) 426
Operator's seat 25
Fuel tank 6
Hydraulic tank 40
Control valve 50
Counterweight 622
X-weight (additional counterweight) 235
Swing motor (including brake valve) 15
Swing circle 59
Swing machinery 26
Center swivel joint 18
Track frame assembly (excluding track shoes) 944
• Track frame 551
• Idler assembly 36 x 2
• Recoil spring assembly 18 x 2
• Carrier roller 3x2
• Track roller 10 x 8
• Travel motor (including reduction gear) 49 x 2
• Sprocket 12 x 2
Track shoe assembly
Rubber shoe (400 mm) 242 x 2
Road liner (400 mm) 269 x 2
Triple grouser shoe (400 mm) 274 x 2

PC45MR-5, PC55MR-5 01-25

WEIGHT TABLE 01 SPECIFICATIONS

Unit: kg
Item PC55MR-5
Boom swing bracket assembly 101
Boom assembly 176
Arm assembly 95
Bucket link assembly 28
Bucket assembly (including side cutter) 121
Blade assembly 210
Boom cylinder assembly 46
Arm cylinder assembly 46
Bucket cylinder assembly 29
Boom swing cylinder assembly 39
Blade cylinder assembly 29
*1: Canopy specification
*2: Cab specification

01-26 PC45MR-5, PC55MR-5

01 SPECIFICATIONS TABLE OF FUEL, COOLANT, AND LUBRICANTS

TABLE OF FUEL, COOLANT, AND LUBRICANTS

For details of notes (Note 1, Note 2...) in the table, see "Operation and Maintenance Manual".

Unit: ℓ
Places to supply oil, coolant, etc. Specified amount Refill capacity
Engine oil pan 8.1 7.5
Final drive case (each on right and left sides) 0.7 0.7
Hydraulic oil system 55 20
Cooling system 8.8 -
Fuel tank 65 -

PC45MR-5, PC55MR-5 01-27

10 STRUCTURE AND FUNCTION

PC45MR-5, PC55MR-5 10-1

CONTENTS 10 STRUCTURE AND FUNCTION

CONTENTS
ABBREVIATION LIST .................................................................................................................................... 10-4
BOOT-UP SYSTEM ..................................................................................................................................... 10-10
LAYOUT DRAWING OF BOOT-UP SYSTEM........................................................................................ 10-10
SYSTEM OPERATING LAMP SYSTEM ............................................................................................... 10-12
SYSTEM OPERATING LAMP SYSTEM DIAGRAM ....................................................................... 10-12
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM ............................................................... 10-12
BATTERY DISCONNECT SWITCH ...................................................................................................... 10-14
FUNCTION OF BATTERY DISCONNECT SWITCH ...................................................................... 10-14
ENGINE SYSTEM ....................................................................................................................................... 10-15
LAYOUT DRAWING OF ENGINE SYSTEM .......................................................................................... 10-15
ENGINE CONTROL SYSTEM .............................................................................................................. 10-16
ENGINE CONTROL SYSTEM DIAGRAM...................................................................................... 10-16
FUNCTION OF ENGINE CONTROL SYSTEM .............................................................................. 10-17
AUTO-DECELERATION SYSTEM ........................................................................................................ 10-20
AUTO-DECELERATION SYSTEM DIAGRAM ............................................................................... 10-20
FUNCTION OF AUTO-DECELERATION SYSTEM........................................................................ 10-20
OPERATION OF AUTO-DECELERATION SYSTEM...................................................................... 10-21
OVERHEAT PREVENTION SYSTEM ................................................................................................... 10-22
OVERHEAT PREVENTION SYSTEM DIAGRAM........................................................................... 10-22
FUNCTION OF OVERHEAT PREVENTION SYSTEM ................................................................... 10-23
AUTOMATIC IDLE STOP SYSTEM ...................................................................................................... 10-24
AUTOMATIC IDLE STOP SYSTEM DIAGRAM.............................................................................. 10-24
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM ...................................................................... 10-24
COMPONENT PARTS OF ENGINE SYSTEM ...................................................................................... 10-26
PTO ............................................................................................................................................... 10-26
COOLING SYSTEM..................................................................................................................................... 10-27
LAYOUT DRAWING OF COOLING SYSTEM ....................................................................................... 10-27
SPECIFICATIONS OF COOLING SYSTEM................................................................................... 10-28
CONTROL SYSTEM.................................................................................................................................... 10-29
LAYOUT DRAWING OF CONTROL SYSTEM ...................................................................................... 10-29
MACHINE MONITOR SYSTEM ............................................................................................................ 10-30
MACHINE MONITOR SYSTEM DIAGRAM.................................................................................... 10-30
KOMTRAX SYSTEM............................................................................................................................. 10-31
KOMTRAX SYSTEM DIAGRAM .................................................................................................... 10-31
FUNCTION OF KOMTRAX SYSTEM ............................................................................................ 10-31
COMPONENT PARTS OF CONTROL SYSTEM................................................................................... 10-32
MACHINE MONITOR..................................................................................................................... 10-32
KOMTRAX TERMINAL .................................................................................................................. 10-40
MACHINE CONTROLLER ............................................................................................................. 10-42
FUEL CONTROL DIAL .................................................................................................................. 10-46
HYDRAULIC SYSTEM................................................................................................................................. 10-48
LAYOUT DRAWING OF HYDRAULIC SYSTEM ................................................................................... 10-48
CLSS .................................................................................................................................................... 10-50
STRUCTURE OF CLSS................................................................................................................. 10-50
FUNCTION OF CLSS .................................................................................................................... 10-51
ENGINE AND PUMP COMBINED CONTROL SYSTEM....................................................................... 10-53
ENGINE AND PUMP COMBINED CONTROL SYSTEM DIAGRAM .............................................. 10-53
FUNCTION OF ENGINE AND PUMP COMBINED CONTROL SYSTEM....................................... 10-54
COMPONENT PARTS OF HYDRAULIC SYSTEM ............................................................................... 10-56
HYDRAULIC TANK ........................................................................................................................ 10-56
MAIN PUMP................................................................................................................................... 10-60
CONTROL VALVE ......................................................................................................................... 10-72
WORK EQUIPMENT SYSTEM ...................................................................................................................10-118
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM .....................................................................10-118
STRUCTURE OF VALVE CONTROL...................................................................................................10-122
PPC LOCK SYSTEM ...........................................................................................................................10-124

10-2 PC45MR-5, PC55MR-5

10 STRUCTURE AND FUNCTION CONTENTS

S/T
Steering
STRG
SIG Signal
SOL Solenoid
STD Standard
OPT
Option
OP
PRESS Pressure
SPEC Specification
SW Switch
TEMP Temperature
T/C Torque Converter
T/M Transmission

PC45MR-5, PC55MR-5 10-9

LAYOUT DRAWING OF BOOT-UP SYSTEM 10 STRUCTURE AND FUNCTION

BOOT-UP SYSTEM
LAYOUT DRAWING OF BOOT-UP SYSTEM
Chassis part

1: Battery 3: KOMTRAX terminal

2: Machine monitor 4: Machine controller

10-10 PC45MR-5, PC55MR-5

10 STRUCTURE AND FUNCTION LAYOUT DRAWING OF BOOT-UP SYSTEM

5: Battery disconnect switch 7: Engine controller

6: System operating lamp

PC45MR-5, PC55MR-5 10-11

SYSTEM OPERATING LAMP SYSTEM 10 STRUCTURE AND FUNCTION

SYSTEM OPERATING LAMP SYSTEM

(Machine with system operating lamp)

SYSTEM OPERATING LAMP SYSTEM DIAGRAM

1: Battery disconnect switch 6: Machine monitor

2: Battery 7: Engine controller
3: Fusible link 8: Machine controller
4: Fuse box 9: KOMTRAX terminal
5: System operating lamp

FUNCTION OF SYSTEM OPERATING LAMP SYSTEM

System operating lamp is lit while any of controllers are in operation. To prevent the abnormal end of the discon-
nection of the battery power supply circuit while the controllers are in operation, check the operation state with
this lamp.
REMARK
• Before shutting off the battery power supply circuit, turn the starting switch to “OFF” position, and check that
the system operating lamp goes off, then turn the battery disconnect switch to “OFF” position.
• If the battery disconnect switch is turned “OFF” (the battery power supply circuit is OFF) while the system
operating lamp is lit, data loss error of controller may occur. Never operate the battery disconnect switch
while the system operating lamp is lit.
• The system operating lamp goes off in 2 minutes after the starting switch is turned to “OFF” position.
• The system operating lamp may be lit while the starting switch is in “OFF” position, because KOMTRAX ter-
minal may maintain its communication under this condition.
System operating lamp being lit and not being lit
• Voltage of 12 V is constantly applied to one side of system operating lamp (LED (Light Emitting Diode)).
• When any controller is in operation, the controller outputs Low (0 V), and a current flows through the diode
and the system operating lamp is lit.
• When all controllers are stopped, the controller outputs High (12 V), and no current flows through the diode
and the system operating lamp is not lit.
REMARK
The system operating lamp may look slightly luminous in the dark when it is not lit. It is due to the minute
leakage of current and this is not an abnormal phenomenon.
• When the starting switch is in “OFF” position, KOMTRAX terminal repeats the start and stop to maintain the
periodic communication.
• The start and stop cycle (sleep cycle) of KOMTRAX terminal varies depending on the factors including the
communication state and machine stop time. So the lamp can be lit as long as approximately 1 hour.

10-12 PC45MR-5, PC55MR-5

10 STRUCTURE AND FUNCTION SYSTEM OPERATING LAMP SYSTEM

REMARK
When you want to cut off the battery circuit for maintenance but the system operating lamp is still lit, turn
the starting switch to “ON” position once, and then turn it to “OFF” position. The lamp goes off in a maxi-
mum of 2 minutes. After system operating lamp goes off, turn the battery disconnect switch immediately to
“OFF” position.
• The engine controller transmits the operation signal to the machine controller during operation, and the ma-
chine controller indicates that the engine controller is in operation.

PC45MR-5, PC55MR-5 10-13

BATTERY DISCONNECT SWITCH 10 STRUCTURE AND FUNCTION

BATTERY DISCONNECT SWITCH

FUNCTION OF BATTERY DISCONNECT SWITCH
(O): OFF position
(I): ON position
• Battery disconnect switch (1) is usually used in the follow-
ing cases in the same purpose of disconnecting the cable
from the negative terminal of the battery.
• When storing the machine for a long period (1 month
or longer)
• When servicing or repairing the electrical system
• When performing electric welding
• When handling the battery
• When replacing the fuse, etc.
• When battery disconnect switch (1) is at OFF position (the contact is opened), all the continuous power
supplies for the components including the starting switch B terminal and controllers are all cut out. It is the
same state as the time when the battery is not connected, and all the electrical system of the machine are
out of operation.
NOTICE
• Do not turn off battery disconnect switch (1) while system operating lamp (2) is lit.
If battery disconnect switch (1) is turned off while system operating lamp (2) is lit, it may erase the
data in the controller, and damage the controller seriously.
• Do not turn off battery disconnect switch (1) while the engine is running or immediately after the en-
gine is stopped.
If battery disconnect switch (1) is turned off while the alternator is generating power, the generated
current has nowhere to go. It leads to over-voltage in the electrical system of the machine, which
may cause serious damage to the electrical system including the electric devices and controllers.
REMARK
• System operating lamp (2) lights up while the controller is in operation. It lights up when KOMTRAX terminal
is performing communication, even if the starting switch is set to OFF position.
• If battery disconnect switch (1) has been off for a long period, the machine monitor and the clock of the radio
may return to the initial state. In this case, resetting is required.

10-14 PC45MR-5, PC55MR-5

10 STRUCTURE AND FUNCTION LAYOUT DRAWING OF ENGINE SYSTEM

ENGINE SYSTEM
LAYOUT DRAWING OF ENGINE SYSTEM

1: Alternator 7: Engine controller

2: Air cleaner 8: KDPF
3: Dust indicator 9: EGR valve
4: Flywheel 10: Fuel filter
5: EGR cooler 11: Engine oil filter
6: Starting motor

PC45MR-5, PC55MR-5 10-15

ENGINE CONTROL SYSTEM 10 STRUCTURE AND FUNCTION

ENGINE CONTROL SYSTEM

ENGINE CONTROL SYSTEM DIAGRAM

1: Battery disconnect switch (*1) 11: Starting motor cut-off relay (for PPC lock)
2: Battery 12: Starting motor cut-off relay (for personal code)
3: Fusible link 13: Fuel control dial
4: Fuse box 14: Starting motor relay
5: Fuse box 15: Starting motor
6: Starting switch 16: Fuel supply pump
7: Engine shutdown secondary switch 17: Various sensors
8: Engine controller 18: Machine monitor
9: Lock lever 19: KOMTRAX terminal
10: PPC lock switch 20: Machine controller
*1: Machine with battery disconnect switch

10-16 PC45MR-5, PC55MR-5

10 STRUCTURE AND FUNCTION ENGINE CONTROL SYSTEM

FUNCTION OF ENGINE CONTROL SYSTEM

Mechanism and function of engine starting system

• When starting switch (6) is turned to ON position, engine controller (8) sends a command current to fuel
supply pump (16).
Accordingly, a fail-safe mechanism is formed and the engine stops in case that the electric system has a
failure.
• When starting switch (6) is turned to START position while lock lever (9) is in LOCK position, the starting
current is supplied to starting motor (15) and the engine starts.
If lock lever (9) is in FREE position, starting motor cut-off relay (11) operates to cut off the starting current to
starting motor (15) and the engine does not start, that is, a neutral safety mechanism.
• Upon receipt of the engine cut-off command from the external source, KOMTRAX terminal (19) sends the
signal to machine monitor (18).
Machine monitor (18) operates starting motor cut-off relay (12) to cut off the starting current to starting mo-
tor (15), thus the engine does not start.

PC45MR-5, PC55MR-5 10-17

ENGINE CONTROL SYSTEM 10 STRUCTURE AND FUNCTION

Mechanism and function of engine speed control system

• Engine controller (8) sends the throttle signal of fuel control dial (13) to machine controller (20).
• Machine controller (20) calculates a proper engine speed from the setting of the work equipment mode and
the condition of the work equipment, and transmits it as the throttle signal to engine controller (8).
• Upon receipt of the throttle signal from machine controller (20), engine controller (8) controls fuel supply
pump (16).
Engine stop mechanism and the function

When starting switch (6) is turned to OFF position, the current from terminal ACC of starting switch (6) to engine
controller (8) is cut off, and the command current to fuel supply pump (16) is also cut off. Fuel supply pump (16)
stops supplying fuel, the engine speed decreases, and the engine stops.

10-18 PC45MR-5, PC55MR-5

10 STRUCTURE AND FUNCTION ENGINE CONTROL SYSTEM

Engine stop mechanism and the function with engine shutdown secondary
switch

When engine shutdown secondary switch (7) is set to the engine stop position, the current from terminal ACC of
starting switch (6) to engine controller (8) is cut off forcibly. The condition becomes the same as that of the time
when starting switch (6) is turned to OFF position, and the engine stops.

PC45MR-5, PC55MR-5 10-19

FUNCTION OF AUTOMATIC IDLE STOP SYSTEM

• Auto idle stop function stops the engine after a certain period of time passed and the operating conditions
are satisfied when the auto idle stop function is enabled.
• The engine stops when the machine controller judges the condition and outputs the engine stop signal with
the auto idle stop function.
• The operating time of the auto idle stop function can be set from the user menu or service menu on the
machine monitor.
Operating conditions of automatic idle stop system
The auto idle stop function operates when all of the following conditions are satisfied at the same time.
• Engine is running.
• Lock lever is in “LOCK” position.
• Working mode is “P”, “E”, “ATT/P”, “ATT/E”, or “B”
• Engine coolant temperature is high (60 °C or above)
• Engine coolant temperature is not overheated (below 107 °C).
• “Auto Idle Stop Timer Set” on machine monitor is not set.
• Machine monitor is not set in service mode. (See “Setting time”.)
• Regeneration of KDPF is not being performed.
• None of the following failure codes is occurring.
Relevant failure codes are as follows.

10-24 PC45MR-5, PC55MR-5

10 STRUCTURE AND FUNCTION AUTOMATIC IDLE STOP SYSTEM

Failure code Failure (displayed on screen)

B@BCNS Eng Water Overheat
#B0118 Cooling water temperature sensor fault (High voltage)
#B0117 Cooling water temperature sensor fault (Low voltage)
DBHQKR Controller Area Network 2 Defective Communication (Mcn Controller)
DB2QKR CAN 2 Defective Communication (Engine Controller)
#B0123 Accelerator sensor 1 (Voltage high)
#B0122 Accelerator sensor 1 (Voltage low)

Setting time
Set the time for the auto idle stop function according to the following items.
For setting of each item, see “TESTING AND ADJUSTING”.

Auto Idle Stop Timer Set(service menu)

Setting Contents of setting
The auto idle stop function does not operate, and the related items are not displayed on service
OFF
menu and user menu.
In Auto Idle Stop Time Fixing menu and Auto Idle Stop Timer Set menu, the selectable shortest
1 minute
time is 1 minute.
In Auto Idle Stop Time Fixing menu and Auto Idle Stop Timer Set menu, the selectable shortest
3 minutes
time is 3 minutes.
In Auto Idle Stop Time Fixing menu and Auto Idle Stop Timer Set menu, the selectable shortest
5 minutes
time is 5 minutes.

Auto Idle Stop Time Fixing (Service menu)

Setting Contents of setting
In Auto Idle Stop Timer Set user menu, operator can select OFF or minimum set time in Auto Idle
Variable
Stop Timer Set to maximum time of 60 minutes. (Default)
OFF The auto idle stop function does not operate, and Auto Idle Stop Timer Set menu is not displayed.
Fix to "x" mi- In the Auto Idle Stop Timer Set menu, the operator can set the time up to "x" minutes (set time at
nutes. left) in the auto idle stop setting time. (Cannot select OFF)

Auto Idle Stop Time Fixing (user menu)

Setting Contents of setting
OFF Auto idle stop function does not operate. (Default)
"y" minutes The engine stops "y" minutes (set time at left) after the lock lever is set to “LOCK” position.

NOTICE
• When "Fix to x min." is selected in the “Auto Idle Stop Time Fixing” menu, the screen changes to the
operator screen automatically and the auto idle stop function operates 60 minutes after the lock lev-
er is set to LOCK position, even when the Service menu is being used.
• When performing work with the Service menu, always check the set value of the auto idle stop func-
tion.

PC45MR-5, PC55MR-5 10-25

COMPONENT PARTS OF ENGINE SYSTEM 10 STRUCTURE AND FUNCTION

COMPONENT PARTS OF ENGINE SYSTEM

PTO
PTO
Abbreviation for Power Take Off

STRUCTURE OF PTO
General view and sectional view

1: Boss 4: Cover
2: Spring pin 5: Main pump
3: Rubber

FUNCTION OF PTO
• PTO reduces the torsional vibration caused by the engine torque fluctuation. PTO also protects the drive
system after the engine from the torsional vibration.
• The power from the engine is transmitted through the flywheel to the coupling rubber (3). The coupling ab-
sorbs the torsional vibration, and the power is transmitted through the boss (1) to the main pump.

10-26 PC45MR-5, PC55MR-5

10 STRUCTURE AND FUNCTION LAYOUT DRAWING OF COOLING SYSTEM

COOLING SYSTEM
LAYOUT DRAWING OF COOLING SYSTEM

A: Oil cooler inlet C: Radiator inlet

B. Oil cooler outlet D: Radiator outlet
1: Oil cooler inlet plug 2: Shroud

PC45MR-5, PC55MR-5 10-27

LAYOUT DRAWING OF COOLING SYSTEM 10 STRUCTURE AND FUNCTION

3: Radiator inlet hose 8: Radiator cap

4: Fan guard 9: Oil cooler
5: Radiator outlet hose 10: Reservoir tank
6: Oil cooler outlet plug 11: Fuel cooler
7: Radiator 12: Drain valve

SPECIFICATIONS OF COOLING SYSTEM

Radiator
Core type: CF90–4
Fin pitch: 3.5/2 mm
Total heat dissipation area: 15.54 m2
Pressure valve cracking pressure: 88.3±14.7 kPa {0.9±0.15 kg/cm2}
Vacuum valve cracking pressure: 0 to 4.9 kPa {0 to 0.05 kg/cm2}
Hydraulic oil cooler
Core type: V-shaped fin
Fin pitch: 3.5/2 mm
Total heat dissipation area: 6.75 m2
Fuel cooler
Core type: Drawn cup
Fin pitch: 3.0/2 mm
Total heat dissipation area: 0.2 m2

10-28 PC45MR-5, PC55MR-5

10 STRUCTURE AND FUNCTION LAYOUT DRAWING OF CONTROL SYSTEM

CONTROL SYSTEM
LAYOUT DRAWING OF CONTROL SYSTEM
Chassis part

1: Fuel control dial 4: Machine controller

2: KOMTRAX GPS antenna 5: KOMTRAX communication antenna
3: KOMTRAX terminal 6: Machine monitor

PC45MR-5, PC55MR-5 10-29

MACHINE MONITOR SYSTEM 10 STRUCTURE AND FUNCTION

MACHINE MONITOR SYSTEM

MACHINE MONITOR SYSTEM DIAGRAM

a: Power supply c: Sensor signal and switch signal

b: CAN signal
1. Machine monitor 4: Engine controller
2: Battery 5: KOMTRAX terminal
3: Machine controller 6: Sensors and switches

10-30 PC45MR-5, PC55MR-5

10 STRUCTURE AND FUNCTION KOMTRAX SYSTEM

KOMTRAX SYSTEM
KOMTRAX SYSTEM DIAGRAM

KOMTRAX system consists of KOMTRAX terminal, communication antenna, and GPS antenna

FUNCTION OF KOMTRAX SYSTEM

• KOMTRAX system transmits various types of information on the machine. KOMTRAX administrator sees
the information in the office and supplies various services to the customers.
• KOMTRAX system can transmits the following information.
• Positional information
• Working information
• Alarm and failure information
• Fuel consumption information
• Maintenance information
• Machine working condition information
REMARK
To provide the services, you need to establish radio station for KOMTRAX separately.

PC45MR-5, PC55MR-5 10-31

COMPONENT PARTS OF CONTROL SYSTEM 10 STRUCTURE AND FUNCTION

COMPONENT PARTS OF CONTROL SYSTEM

MACHINE MONITOR
FUNCTION OF MACHINE MONITOR

• The machine monitor has monitor display function and mode selection function.
• CPU (Central Processing Unit) is installed inside the machine monitor, and it processes, displays, and out-
puts the information.
• The monitor system monitors the machine state by obtaining the information with the sensors and switches
installed in various parts of the machine, processes the information instantly. It displays the information on
the machine monitor to inform the operator of the machine condition.
The followings are categories which contents displayed on the machine monitor are broadly divided into.
• Alarms when the machine has a trouble
• Machine state (engine coolant temperature, fuel level, etc.)
• The switches on the machine monitor have functions to control the machine.

10-32 PC45MR-5, PC55MR-5

10 STRUCTURE AND FUNCTION COMPONENT PARTS OF CONTROL SYSTEM

REMARK
• It consists of display and function switches. The display adopts LCD (Liquid Crystal Display), and the func-
tion switches part is flat sheet switch.
• If there is any abnormality in the machine monitor, controller, or wiring between the machine monitor and
controller, the machine monitor does not display correctly.
• An LCD panel sometimes shows black spots (spots that remain unlit) and bright spots (spots that do not go
off) as one of the characteristics. When there are fewer than 10 black or white spots, this is not a failure or a
defect.
• The battery voltage may drop sharply when the engine is started depending on the ambient temperature and
battery condition. In this case, the display may disappear a while, but it is not an abnormal phenomenon.
• When the machine monitor is used continuously, blue bright spots may appear on the black background, but
it is neither failure nor malfunction.
The background color of the display is usually blue or white, so the blue bright spots will not be a problem.
(Red, green, blue are used for display of the white.)
• For the following items, see “Operation and Maintenance Manual”.
• Screen display
• Guidance icons, function switches

INPUT AND OUTPUT SIGNALS OF MACHINE MONITOR

070-12P “F15”
Input and output sig-
Pin No. Signal name
nals
1 Continuous power supply (12 V) Input
2 Ground (return) -
3 Starting switch (ACC) Input
4 Starting motor cut-off relay (for personal code) Output
5 External buzzer Output
6 Continuous power supply (12 V) Input
7 Ground (return) -
8 Engine shutdown secondary switch Input
9 External starting signal Input
10 System operating lamp Output
11 CAN0_H (with built-in terminating resistor 120 Ω) Input and output
12 CAN0_L (with built-in terminating resistor 120 Ω) Input and output

PC45MR-5, PC55MR-5 10-33

COMPONENT PARTS OF CONTROL SYSTEM 10 STRUCTURE AND FUNCTION

TYPES OF GAUGES AND METERS DISPLAYED ON MACHINE MONITOR

Item to be dis-
Gauge Range and method for display Remarks
played
Monitor • Indicates corresponding tempera-
Tempera-
Range back- ture range.
ture
ground
• Alarm buzzer sounds when the
Engine coolant W1 110 °C Red temperature exceeds 110 °C.
temperature
gauge W2 107 °C Red • If the background color of monitor
is white, perform warm-up opera-
(*1) W3 105 °C Blue tion.
W4 86 °C Blue
W5 59 °C White
Monitor Indicates the remaining quantity.
Range Quantity back-
ground
F1 56.0 ℓ Blue
Fuel gauge
F2 46.0 ℓ Blue
(*1)
F3 33.6 ℓ Blue
F4 17.2 ℓ Blue
F5 13.7 ℓ Red
Segment Load level Indicates instantaneous fuel consump-
tion (average of fuel consumption by 3
Light to
Green 1 to 8 seconds) in 10 steps.
ECO gauge medium
(Displayed when Operation Record →
(*2) Configurations → ECO Gauge on user
Orange 9, 10 Heavy menu is set to ON.)

Indicates accumulated engine operating

hours.
Service meter 00000.0 h to 99999.9 h
(Press F2 switch to change to clock dis-
play.)
Displays the time.
• 12-hour display (AM/PM)
Clock (Press F2 switch to change to service
• 24 hour display meter display.)

Indicates average fuel consumption.

Fuel consump- • 1 day
(Display can be switched by selecting
tion gauge • Split Time another item in Operation Record →
(*2) • None Configurations → Average Fuel Con-
sumption Display on user menu.)

*1: The gauge disappears if the gauge signal is not available due to an open circuit in the CAN communication
line.
*2: Display can be switched by selecting another item in “Operation Record” → “Configurations” on the user
menu.

10-34 PC45MR-5, PC55MR-5

10 STRUCTURE AND FUNCTION COMPONENT PARTS OF CONTROL SYSTEM

TYPES OF CAUTION LAMPS DISPLAYED ON MACHINE MONITOR

Range and method for display

Item to be Caution
Symbol lamp display Action level Remarks
displayed Range
(background display
color)
Min. 107 °C Lit (red) L02 • Caution lamp background
color changes depending
Min. 60 °C, be-
Lit (blue) - on the temperature detect-
low 107 °C
ed.
Engine cool-
• Alarm buzzer sounds when
ant tempera-
the temperature exceeds
ture
110 °C.
Below 60 °C Lit (white) -
• If the background color of
caution lamp is white, per-
form warm-up operation.
Below 13.8 ℓ Lit (red) - • The background color of
caution lamp changes de-
Fuel level
Min. 13.8 ℓ Lit (blue) - pending on the fuel level.

When charging • Caution lamp lights up and

Battery was faulty alarm buzzer sounds when
Lit (red) L03
charge (below specified an abnormality is detected
voltage) while engine is running.
When it is abnor- • Caution lamp lights up and
mal alarm buzzer sounds when
Engine oil (when pressure an abnormality is detected
Lit (red) L03
pressure is below the while engine is running.
specified pres-
sure)
When mainte- • The display changes de-
nance due time Lit (red) - pending on how long it has
is over passed since the mainte-
nance due time was over.
Maintenance
due time • After starting switch is
When mainte-
warning nance notice turned to ON position, cau-
time is over Lit (yellow) - tion lamp lights up when
condition is satisfied for
(*1)
lighting up, and then it goes
out in 30 seconds.
When action lev- • Caution lamp lights up
el L04 or L03 is Lit (red) L04 or L03 when an abnormality is de-
State of sys- detected tected in machine system.
tem When action lev- • When the background color
L01
el L01 is detect- Lit (yellow) of caution lamp is red, the
ed (*2) warning buzzer sounds.

PC45MR-5, PC55MR-5 10-35

COMPONENT PARTS OF CONTROL SYSTEM 10 STRUCTURE AND FUNCTION

Range and method for display

Item to be Caution
Symbol lamp display Action level Remarks
displayed Range
(background display
color)
When action lev- • Caution lamp lights up
el L04 or L03 is Lit (red) L04 or L03 when an abnormality is de-
State of en- detected tected in engine system.
gine system When action lev- • When the background color
L01
el L01 is detect- Lit (yellow) of caution lamp is red, the
ed (*2) warning buzzer sounds.
When action lev- • Caution lamp lights up
el L04 or L03 is Lit (red) L04 or L03 when abnormality is detect-
State of hy- detected ed in hydraulic system.
draulic sys-
tem When action lev- L01 • When the background color
el L01 is detect- Lit (yellow) of caution lamp is red, the
ed (*2) warning buzzer sounds.
When action lev- • Caution lamp lights up
el L04 or L03 is Lit (red) L04 or L03 when an abnormality is de-
State of detected tected in KDPF system.
KDPF sys-
tem When action lev- L01 • When the background color
el L01 is detect- Lit (yellow) of caution lamp is red, the
ed (*2) warning buzzer sounds.
When action lev- • Caution lamp lights up
el L04 or L03 is Lit (red) L03 when soot is accumulated
detected in KDPF or when purifying
KDPF soot function detects an abnor-
accumula- mality.
tion When action lev- L01
el L01 is detect- Lit (yellow) • When the background color
ed (*2) of caution lamp is red, the
warning buzzer sounds.
• Caution lamp lights up and
Engine When engine warning buzzer sounds
Lit (red) L02
Overrun overruns when engine overrun is de-
tected.

Seat belt Seat belt is not

- -
caution lamp fastened

When action lev- • Caution lamp lights up

el L04 is detect- Lit (red) L04 when abnormality is detect-
ed ed in the machine.
When action lev- • When the background color
el L03 is detect- Lit (red) L03 of caution lamp is red, the
ed warning buzzer sounds.
Action level
When action lev-
el L02 is detect- Lit (red) L02
ed
When action lev- L01
el L01 is detect- Lit (yellow)
ed (*2)

10-36 PC45MR-5, PC55MR-5

10 STRUCTURE AND FUNCTION COMPONENT PARTS OF CONTROL SYSTEM

*1: Maintenance notice time can be changed on “Maintenance Mode Setting” of SERVICE MODE.
*2: These items are lit for 2 seconds, and then go out.

TYPES OF PILOT LAMPS DISPLAYED ON MACHINE MONITOR

Item to be Remarks
Symbol Range and method for display
displayed
• Operates automati- • Displays the operation
cally when temper- state of preheating.
ature is low.
(The lamp is lit for
Preheating Automatic preheating approximately 15
seconds at maxi-
mum.)
• Goes out after en-
gine is started.

Lit: Aftertreatment devices regeneration in progress • Indicates regeneration

Aftertreat-
state of aftertreatment
ment devices Not lit: Aftertreatment devices regeneration has been
regeneration devices.
completed.

• Indicates regeneration
state of aftertreatment
Aftertreat- devices.
Lit: Aftertreatment devices regeneration is disabled
ment devices • When manual station-
regeneration Not lit: Aftertreatment devices regeneration disable is
ary regeneration is
disable canceled
necessary, KDPF soot
accumulation monitor
lights up.
• Indicates the state of
Message Lit: There is an unread message messages.
(Unread) Not lit: No message

Message • Indicates the state of

(Not yet re- Lit: There is a read and unreplied message. messages.
plied, al- Not lit: No message
ready-read)
• Displays the operation
Auto-deceler- Lit: ON of auto-deceleration
ation Not lit: OFF function

P: Heavy-duty operation • Displays the working

E: Low-fuel consumption operation mode.
Working B: Breaker operation
mode ATT/P: 2-way attachment operation
ATT/E: 2-way attachment operation with low fuel con-
sumption
• Displays the set mode
Lo: Low-speed travel of travel speed.
Travel speed
Hi: High-speed travel

PC45MR-5, PC55MR-5 10-37

COMPONENT PARTS OF CONTROL SYSTEM 10 STRUCTURE AND FUNCTION

OPERATOR MODE FUNCTION OF MACHINE MONITOR

These items are normally displayed. The operator can display, set these items with switch operation. Some
items may require special switch operation.
Items available in the operator mode are as follows.
Catego- Patterns for dis-
ry Item play (*2)
(*1)
W X Y Z
Display of KOMATSU logo
1 1 1 1
Display of password input 2 - - -
Display of service person identification state 3 - - -
A Display of maintenance due time over - - - 2
Display to check working mode and travel speed 4 2 2 3
Display of standard screen 5 3 3 4
Display of engine shutdown secondary switch screen
Display of end screen
Selection of auto-deceleration
Selection of working mode
Selection of travel speed
Stop operation of alarm buzzer
Operation to display clock and service meter
Check of maintenance information
B
Setting and display of user menu
• Operation Record
• Machine Setting
• Aftertreatment Devices Regeneration
• Maintenance
• Monitor Setting
• Display of message (including KOMTRAX messages for user)
Caution lamp
C Display of KDPF regeneration
Action level and failure code
Checking function of LCD (Liquid Crystal Display)
D Checking function of service meter
Function of usage limitation setting and password change

*1: The operator mode items are classified as follows.

A: Display from the time when the starting switch is turned to “ON” position to the time when display changes to
the standard screen, and display after starting switch is turned to “OFF” position
B: Display when the machine monitor switch is operated
C: Display when condition is satisfied
D: Display that requires special switch operation.

10-38 PC45MR-5, PC55MR-5

10 STRUCTURE AND FUNCTION COMPONENT PARTS OF CONTROL SYSTEM

*2: The sequence of display from the time when the starting switch is turned to “ON” position to the time when
the standard screen appears varies depending on the settings and conditions of the machine as follows:
W: When the engine start lock is enabled.
X: When the engine start lock is disabled.
Y: When any abnormality is detected by the check before starting
Z: When any item is detected as the maintenance due time is over
REMARK
• For how to operate the operator mode functions, see “Operation and Maintenance Manual”.
• For the operating method of the engine start lock function, see“ Password setting and canceling manual”.

SERVICE MODE FUNCTION OF MACHINE MONITOR

These functions are not displayed normally. A technician can display and set them special operation of
switches. These functions are used for special settings, testing, adjusting, or troubleshooting.
Items available in the service mode are as follows:
REMARK
For operating method of the service mode functions, see TESTING AND ADJISTING, “SERVICE MODE”.
Pre-defined Monitoring
Self-define Monitoring
Abnormality Record Mechanical Sys Abnormality Record
Electrical Sys Abnormality Record
Maintenance Record
Maintenance Mode Setting
Phone Number Entry
Default Key-on mode
Unit
With/Without Attachment
Auto Idle Stop Time Fixing
Diagnostic Tests Cylinder Cutout Mode Operation
Active Regeneration for Service
KDPF Memory Reset
Rail Pressure Memory Reset
Adjustment Pump Absorption Torque
Attachment EPC 2 Adjustment
Attachment EPC 3 Adjustment
Batt. Disconnect Set
KOMTRAX Settings Terminal Status
GPS & Communication State
Modem Information
Service Message

PC45MR-5, PC55MR-5 10-39

COMPONENT PARTS OF CONTROL SYSTEM 10 STRUCTURE AND FUNCTION

KOMTRAX TERMINAL
STRUCTURE OF KOMTRAX TERMINAL
General view
Model: TC630/TC635

1: GPS antenna connection 4: Communication antenna connection

2: Machine harness connection (070-18P) 5: LED lamp display
3: Machine harness connection (070-12P)

FUNCTION OF KOMTRAX TERMINAL

• This terminal uses the communication technology of cell phone.
• This terminal is the wireless communication equipment which enables to transmit GPS locational informa-
tion and various machine information which is received from network signal or input signal. It can transmit
the information via communication antenna.
• The condition of KOMTRAX terminal can be checked on the “KOMTRAX Setting” screen in the service
mode of the machine monitor.
• Use of KOMTRAX terminal must be limited for the countries in which such communication is allowed.
• The terminal has LED lamps and 7-segment lamp indicator used for testing and troubleshooting on its dis-
play section.
REMARK
• When commencing the operation of the KOMTRAX system or changing the country in which the system is
used, you must give notice to Komatsu Ltd.
• When operating the system in Japan, it is required to install a terminal for exclusive use in Japan.

INPUT AND OUTPUT SIGNALS OF KOMTRAX TERMINAL

070-18P“CK01”
Pin No. Signal name Input and output signals
1 (*1) -
2 (*1) -
3 (*1) -
4 (*1) -
5 (*1) -
6 (*1) -
7 (*1) -
8 (*1) -

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10 STRUCTURE AND FUNCTION COMPONENT PARTS OF CONTROL SYSTEM

Pin No. Signal name Input and output signals

9 (*1) -
10 CAN (C)_H Input and output
11 CAN (C)_L Input and output
12 (*1) -
13 (*1) -
14 External starting signal Input and output
15 System operating lamp Output
16 (*1) -
17 (*1) -
18 (*1) -

*1: Never connect these pins, otherwise it may cause malfunction or failures.
070-12P“CK02”
Pin No. Signal name Input and output signals
1 GND -
2 GND -
3 Starting switch (ACC) Input
4 Alternator (R) Input
5 (*1) -
6 Power supply Input
7 Power supply Input
8 (*1) -
9 (*1) -
10 (*1) -
11 Starting switch (C) Input
12 (*1) -

*1: Never connect these pins, otherwise it may cause malfunction or failures.

PC45MR-5, PC55MR-5 10-41

*1: Never connect these pins. It may cause malfunction or failures.

PC45MR-5, PC55MR-5 10-45

COMPONENT PARTS OF CONTROL SYSTEM 10 STRUCTURE AND FUNCTION

FUEL CONTROL DIAL

STRUCTURE OF FUEL CONTROL DIAL
Fuel control dial is installed in the R.H. console box.
General view and sectional view

1: Potentiometer 3: Knob
2: Spring

FUNCTION OF FUEL CONTROL DIAL

When knob (3) is turned, the shaft of potentiometer (1) rotates. The resistance of variable resistor in potentiome-
ter (1) varies according to this rotation, and throttle signals are sent to the controller.

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10 STRUCTURE AND FUNCTION COMPONENT PARTS OF CONTROL SYSTEM

REMARK
The hatched area in the following graph is the abnormality de-
tection area. When the throttle voltage is in this area, the en-
gine speed is set to high idle.

PC45MR-5, PC55MR-5 10-47

LAYOUT DRAWING OF HYDRAULIC SYSTEM 10 STRUCTURE AND FUNCTION

HYDRAULIC SYSTEM
LAYOUT DRAWING OF HYDRAULIC SYSTEM
Chassis part

1: Hydraulic tank 7: Engine controller

2: Fuel supply pump 8: LS valve
3: Travel PPC pressure sensor 9: Servo valve
4: Work equipment PPC pressure switch 10: PC-EPC valve
5: Swing parking brake pressure sensor 11: PC valve
6: Control valve 12: Main pump

10-48 PC45MR-5, PC55MR-5

10 STRUCTURE AND FUNCTION LAYOUT DRAWING OF HYDRAULIC SYSTEM

Around cab and floor

1: Machine monitor 4: Machine controller

2: Fuel control dial 5: Pump secondary drive switch
3: Starting switch

PC45MR-5, PC55MR-5 10-49

CLSS 10 STRUCTURE AND FUNCTION

CLSS
CLSS
Abbreviation for Closed-center Load Sensing System

STRUCTURE OF CLSS

Features of CLSS
• Fine controllability not influenced by load
• Control performance that allows digging even under fine control operation condition
• Easy combined operation ensured by the flow dividing performance that is determined by the opening
areas of spools during combined operations
• Energy saving by variable discharge pump control
Composition of CLSS
• CLSS consists of variable displacement piston pump, control valves, and respective actuators.
• The main pump consists of a pump body, PC valve, and LS valve.

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10 STRUCTURE AND FUNCTION CLSS

FUNCTION OF CLSS
Control of pump swash plate angle
CLSS controls the pump swash plate angle (pump discharged
volume) so that LS differential pressure (∆PLS) will be con-
stant, which is the differential pressure between pump dis-
charged pressure (PP) and control valve outlet LS pressure
(PLS) (actuator load pressure).
“LS differential pressure (∆PLS) = Pump discharged pressure
(PP) - LS pressure (PLS)”
• The pump swash plate shifts toward the maximum angle
position when LS differential pressure (∆PLS) is lower than
the set pressure of the LS valve (when the actuator load
pressure is high).
• The pump swash plate shifts toward the minimum angle
position when LS differential pressure is higher than the
set pressure (when the actuator load pressure is low).

LS differential pressure (∆PLS) and pump

swash plate angle
REMARK
For details of the operation, see “MAIN PUMP”.

PC45MR-5, PC55MR-5 10-51

CLSS 10 STRUCTURE AND FUNCTION

Pressure compensation control

• A pressure compensation valve is installed to the inlet port side of the control valve in order to balance the
load.
• When actuators are operated in combined operations, the pressure difference (∆P) between the upstream
(inlet port) and downstream (outlet port) of the spool of each valve is kept the same regardless the size of
the load (pressure).
• The oil flow from the pump is divided (compensated) in proportion to the open areas (S1) and (S2) of each
valve.

10-52 PC45MR-5, PC55MR-5

10 STRUCTURE AND FUNCTION ENGINE AND PUMP COMBINED CONTROL SYSTEM

ENGINE AND PUMP COMBINED CONTROL SYSTEM

ENGINE AND PUMP COMBINED CONTROL SYSTEM DIAGRAM

Input and output signals

a: PC-EPC valve drive signal f: Oil pressure switch signal
b: Solenoid valve GND g: 1st throttle signal
c: CAN signal h: Fuel supply pump control signal
d: CAN signal i: Various sensor signals
e: Oil pressure sensor signal
1: Battery disconnect switch 12: Various sensors
2: Battery 13: Oil pressure sensor
3: Fusible link 14: Oil pressure switch
4: Fuse box 15: Main pump
5: Resistor for PC-EPC valve 15a: Servo
6: Machine controller 15b: LS valve
7: Engine controller 15c: PC valve
8: Machine monitor 16: Control valve
9: Pump secondary drive switch 16a: Merge-divider valve
10: Fuel control dial 17: PC-EPC valve
11: Fuel supply pump 18: Starting switch

PC45MR-5, PC55MR-5 10-53

ENGINE AND PUMP COMBINED CONTROL SYSTEM 10 STRUCTURE AND FUNCTION

FUNCTION OF ENGINE AND PUMP COMBINED CONTROL SYSTEM

Working mode selection function
• The operator can select one from five working modes of P,
E, B, ATT/P, and ATT/E in the working mode on machine
monitor.
• Operator can select the most appropriate engine torque
(T) and pump absorption torque according to the work.
• When “Without Attachment” is selected in “With/Without
Attachment” items of “Default” in Service mode, the select-
able modes are 2 of P and E.
• The machine controller obtains the pump absorption upper
limit torque by calculating the engine speed being set with
the working mode and the fuel control dial and the actual
engine speed. It controls the pump so that the engine
speed is kept around the matching point set in each mode
even when the heavy load is applied.
• When the engine speed decreases, it reduces the pump
absorption torque to prevent engine from being stopped.

Control method in each mode

Working mode Matching point
P, ATT/P (during operation), B 28.2 kW/2375 rpm{37.8 HP/2375 rpm}
E, ATT/E (during operation) 22.6 kW/1896 rpm{30.3 HP/1896 rpm}

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10 STRUCTURE AND FUNCTION ENGINE AND PUMP COMBINED CONTROL SYSTEM

• In mode P, E, ATT/P, or ATT/E, B, the engine speed is kept

around the matching point set in each mode.
• As the load of the pump increases, and the pump dis-
charged pressure increases, the engine speed decreases.
• The machine controller raises the engine speed to near
the matching point in order to reduce the discharged vol-
ume of the pump.
• As the load of the pump decreases and the pump dis-
charged pressure decreases, the pump discharged volume
increases until the engine speed comes to near the match-
ing point.

Control function when pump secondary drive switch is ON

When the main pump does not operate normally, and machine
does not work due to an abnormality occurring in the controller,
etc., operate the pump drive secondary switch (1). With this op-
eration, temporary work can be performed with absorption tor-
que to mode E. At this time, only PC-EPC valve senses the oil
pressure since a constant current flows from the battery to PC-
EPC valve.
REMARK
Pump drive secondary switch (1) is an alternative type. If the
machine is operated with this switch at emergency (a) position
while the machine is normal, action level L03 appears on the
display.
a: Emergency (when abnormal)
b: Normal (when normal)

PC45MR-5, PC55MR-5 10-55

COMPONENT PARTS OF HYDRAULIC SYSTEM 10 STRUCTURE AND FUNCTION

COMPONENT PARTS OF HYDRAULIC SYSTEM

HYDRAULIC TANK
STRUCTURE OF HYDRAULIC TANK
General view

1: Hydraulic tank 4: Sight gauge

2: Oil filler cap 5: Drain plug
3: Breather

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10 STRUCTURE AND FUNCTION COMPONENT PARTS OF HYDRAULIC SYSTEM

Sectional view

6: Filter 8: Cyclone assembly

7: Bypass valve 9: Strainer

SPECIFICATIONS OF HYDRAULIC TANK

Hydraulic tank capacity: 33 ℓ
Hydraulic tank refill capacity: 20 ℓ
Bypass valve set pressure: 0.25±0.05 MPa {2.5±0.5 kg/cm2}

PC45MR-5, PC55MR-5 10-57

COMPONENT PARTS OF HYDRAULIC SYSTEM 10 STRUCTURE AND FUNCTION

OPERATION OF CYCLONE ASSEMBLY

1. The hydraulic oil returning from each actuator flows through the filter to block (1) of the cyclone assembly.
2. The hydraulic oil flows from block (1) into the cylindrical part of cyclone (2) increasing the speed, and the
flow becomes swirls.
3. A centrifugal force is generated as the hydraulic oil swirls, and bubbles with a lower specific gravity gather
together to the center.
4. The hydraulic oil and air are separated by discharging the collected bubbles into the hydraulic oil in the tank
through the upper center of block (1) and outlet (a) on the side of cyclone (2).
5. The hydraulic oil containing no bubble is discharged through outlet (b) at the bottom of cyclone (2), and
then it flows through the strainer into the main pump again.

HYDRAULIC TANK OIL FILLER CAP

STRUCTURE OF HYDRAULIC TANK OIL FILLER CAP
1:Filter element
2:Bottom plate
3:Gasket
4:Seam valve
5:Spring

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10 STRUCTURE AND FUNCTION COMPONENT PARTS OF HYDRAULIC SYSTEM

FUNCTION OF HYDRAULIC TANK OIL FILLER CAP

Prevention of pressure rise in hydraulic tank
The pressure in the hydraulic tank increases as the oil level and the temperature in the hydraulic tank rise corre-
sponding to the operation of the hydraulic cylinders while the hydraulic circuit is in operation. To prevent this
from occurring, bottom plate (1) is pushed up to release the pressure in the tank and prevent pressure from ris-
ing when the pressure in the tank exceeds the set pressure.
Pressure valve cracking pressure: 38±15 kPa {0.39±0.15 kg/cm2}

HYDRAULIC TANK BREATHER

STRUCTURE OF HYDRAULIC TANK BREATHER
Sectional view
1: Nut
2: Cover
3: Filter element
4: Case
5: Valve assembly
6: Body

FUNCTION OF HYDRAULIC TANK BREATHER

Prevention of negative pressure in hydraulic tank
Negative pressure is generated if the oil level in the hydraulic tank lowers since it is pressurized and airtight. To
prevent this from occurring, the valve assembly (5) is opened by the differential pressure from the barometric
pressure, and the barometric pressure is taken in.
(Set pressure of intake valve : 0.002±0.0003 MPa {0.02±0.003 kg/cm2} )
(Set pressure of exhaust valve: 0.1±0.015 MPa {1.0±0.15 kg/cm2} )

PC45MR-5, PC55MR-5 10-59

COMPONENT PARTS OF HYDRAULIC SYSTEM 10 STRUCTURE AND FUNCTION

MAIN PUMP
STRUCTURE OF MAIN PUMP
General view

P1: Pump discharge port P3: Swing and blade pump discharge port
P1L: Pump pressure input port (from control valve port P4: Pilot pressure output port
PP) PLS: LS pressure input port (from control valve port
P1T: Travel deviation adjustment orifice LS)
P2: Pump discharge port PS: Main pump suction port
P2T: Travel deviation adjustment orifice

10-60 PC45MR-5, PC55MR-5

10 STRUCTURE AND FUNCTION COMPONENT PARTS OF HYDRAULIC SYSTEM

1: Main pump 5: EPC valve

2: Servo valve 6: Bleeder
3: Swing and blade pump 7: Maximum delivery adjustment plug
4: Pilot pump 8: Minimum delivery adjustment plug
Sectional view

GH: Swing and blade pump Hi signal port PE: Control piston pressure port
GL: Swing and blade pump Lo signal port PEPC: EPC source pressure input port
PAVE: Pump average pressure port PH: Pump shuttle pressure port
PDE: EPC drain port
1: Shaft 7: Cylinder block
2: Case 8: Valve plate
3: Cap 9: Servo piston
4: Rocker cam 10: Ball retainer
5: Shoe 11: Oil seal
6: Piston

PC45MR-5, PC55MR-5 10-61

COMPONENT PARTS OF HYDRAULIC SYSTEM 10 STRUCTURE AND FUNCTION

Structure

• This pump consists of a variable capacity swash plate piston pump, Swing and blade pump pilot pump and
servo valve.
• Cylinder block (7) is supported on shaft (1) by spline (a).
• Shaft (1) is supported by each bearing at the front and rear.
• The tip of piston (6) is shaped as a concave sphere and is crimped together with shoe (5).
• Piston (6) and shoe (5) form a spherical bearing.
• Rocker cam (4) has flat surface (A), and shoe (5) is always pressed against this surface while sliding in a
circular pattern.
• Rocker cam (4) is supported on ball retainer (10) installed to case (2).
• Shoe (5) leads high-pressure oil to flat surface (A) of rocker cam (4) and form a static pressure bearing for
its sliding.
• Piston (6) reciprocates in the axial directions inside each cylinder of cylinder block (7).
• Cylinder block (7) rotates relatively to valve plate (8) while sealing the pressurized oil.
The oil pressure is balanced properly on this surface.
• The pressurized oil is sucked in and discharged from each cylinder chamber in cylinder block (7) through
valve plate (8).

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10 STRUCTURE AND FUNCTION COMPONENT PARTS OF HYDRAULIC SYSTEM

• Cylinder block (7) is with even numbers of holes. Each one cocoon shape port out of every two ports on the
surface contacting to valve plate (8) is connected to the long cocoon shape port of valve plate (8).
• Two long cocoon shape ports on valve plates (8) correspond to two discharging ports which act as a double
pump.

FUNCTION OF MAIN PUMP

• This pump converts the engine speed and torque transmitted to the shaft of the pump into hydraulic pres-
sure, and discharges pressurized oil corresponding to the load.
• The discharged volume changes as the swash plate angle changes.
• There are 2 pump discharge ports, and each pump can supply pressurized oil separately.
• It acts as a single pump after the pressurized oil merged at the control valve for the operation other than
traveling.
• Two discharging ports are connected to right travel and left travel respectively when traveling (divided
mode).
• The pressures of the left travel and right travel are basically the same and the function is the same as that
of a single pump although it is divided mode when driving straight (with combined operation of traveling and
the work equipment operation, it is merged mode).
• The pump pressure of the outside track increases, and that of the inside decreases at steering operation
during traveling. These two pressures are generated inside the pump (the pressure of the port with an even
number is high, and that of the port with an uneven number is low in cylinder block).
• The difference among the pressures is generated in divided mode only when operating steering during trav-
eling. It is a special kind of state.
• The average discharged pressure among the two pumps controls the PC valve.
Superiority of the double pump system
• It is the characteristic of the usual pump system that the motor pressure on the driven side become the
same as the motor pressure on the driving side as the pressure compensation valve of control valve acts.
That is, the pressure compensation valve on the driven side is throttled, and the pressure of the driven side
circuit increases to be the same as that of the driving side circuit.
• Normally, the motor pressure on the driving side (outside) increases, and that on the driven side (inside)
decreases in the double pump system when operating steering during traveling.
The motor pressure on the driven side remains low, and it prevents the flow rate of the motor on the driving
side from being decreased.
Example of the engine output of the single pump system
• When driving straight
The pressure on the right 9.80 MPa {100 kg/cm2} ) x the flow rate on the right (50.0 ℓ/min) + the pressure on
the left (9.80 MPa {100 kg/cm2} ) x the flow rate on the left (50.0 ℓ/min) = 8.1 kW {10.9 HP} + 8.1 kW
{10.9 HP} = 16.2 kW {21.7 HP}
• When operating steering
The pressure on the right 19.6 MPa {200 kg/cm2} ) x the flow rate on the right (50.0 ℓ/min) + the pressure on
the left (9.80 MPa {100 kg/cm2} ) x the flow rate on the left (40.0 ℓ/min) = 16.2 kW {21.7 HP} + 6.6 kW
{8.9 HP} = 22.8 kW {30.6 HP}
• When engine stop is being prevented (when the horsepower inputted in the pump is larger than the engine
horsepower, and the engine control is starting)
The pressure on the right 19.6 MPa {200 kg/cm2} ) x the flow rate on the right (30.0 ℓ/min) + the pressure on
the left (19.6 MPa {200 kg/cm2} ) x the flow rate on the left (20.0 ℓ/min) = 9.6 kW {12.9 HP} + 6.6 kW
{8.9 HP} = 16.2 kW {21.7 HP}
The average of the right and left flow rate has dropped from 50.0 ℓ/min to 25.0 ℓ/min (it has been decreased by
50.0 %).
Example of the engine output of the double pump system
• When driving straight

PC45MR-5, PC55MR-5 10-63

COMPONENT PARTS OF HYDRAULIC SYSTEM 10 STRUCTURE AND FUNCTION

The pressure on the right 9.80 MPa {100 kg/cm2} ) x the flow rate on the right (50.0 ℓ/min) + the pressure on
the left (9.80 MPa {100 kg/cm2} ) x the flow rate on the left (50.0 ℓ/min) = 8.1 kW {10.9 HP} + 8.1 kW
{10.9 HP} = 16.2 kW {21.8 HP}
• When operating steering
The pressure on the right 19.6 MPa {200 kg/cm2} ) x the flow rate on the right (50.0 ℓ/min) + the pressure on
the left (4.90 MPa {50 kg/cm2} ) x the flow rate on the left (40.0 ℓ/min) = 16.2 kW {21.7 HP} + 2.9 kW
{3.9 HP} = 19.1 kW {25.6 HP}
• When engine stop is being prevented (when the horsepower inputted in the pump is larger than the engine
horsepower, and the engine control is starting)
The pressure on the right 19.6 MPa {200 kg/cm2} ) x the flow rate on the right (43.0 ℓ/min) + the pressure on
the left (4.9 MPa {50 kg/cm2} ) x the flow rate on the left (33.0 ℓ/min) = 14.0 kW {18.8 HP} + 2.2 kW
{3.0 HP} = 16.2 kW {21.8 HP}
The average of the right and left flow rate has dropped from 50.0 ℓ/min to 38.0 ℓ/min (it has been decreased by
24.0 %).
The decrease of the flow rate when engine stop is being prevented is 24.0 % with the double pump system. It is
lower than 50.0 % which would be obtained with the single pump system.

OPERATION OF MAIN PUMP

Selection of discharged volume (selection of swash plate angle)
1. Cylinder block (7) rotates together with shaft (1), and shoe
(5) slides on plane (A).
2. The leaning (a) between the center line (X) of rocker cam
(4) and cylinder block (7) changes as rocker cam (4) pivots
on ball retainer (10), and leans.
3. (a) is called the swash plate angle.

Suction and discharge of pressurized oil

1. While angle (a) is made between center line (X) of rocker
cam (4) and the axis of cylinder block (7), flat surface (A)
works as a cam for shoe (5).
2. Piston (6) reciprocates in cylinder block (7).
3. Difference is made between volumes (E) and (F) in cylin-
der block (7) since cylinder block (7) moves rotationally
along face (A) of the rocker cam.
4. The oil in amount of (F) minus (E) per each piston (6) is
suctioned in and discharged from.
5. As cylinder block (7) rotates and the volume of chamber
(E) decreases, pressurized oil is discharged on the proc-
ess.
6. As the volume of chamber (F) increases, pressurized oil is
suctioned on the process.

10-64 PC45MR-5, PC55MR-5

10 STRUCTURE AND FUNCTION COMPONENT PARTS OF HYDRAULIC SYSTEM

State where no suction of pressurized oil or discharge (swash plate angle = 0)

1. The difference between volumes (E) and (F) inside cylin-
der block (7) is zero when center line (X) of rocker cam (4)
matches the axis of cylinder block (7) (the swash plate an-
gle is zero).
2. Suction and discharge of pressurized oil is not performed
in this stage. Namely pumping action is not performed.
(Angle of swash plate never becomes zero actually)
3. Pump discharged volume is in proportion to swash plate
angle (a).
4. There are an even number of holes (10 pieces) on cylinder
block (7), and they match the two grooves of valve plate
(8) alternately. The oil of quantity for five pistons is dis-
charged respectively through each pump discharge port.

Control of the discharged volume

1. As swash plate angle (a) increases, the difference be-
tween volumes (E) and (F) increases, then discharged vol-
ume (Q) increases.
2. Swash plate angle (a) is changed by servo piston (9).
3. Servo piston (9) moves in a linear reciprocating motion
corresponding to the signal pressure from the PC valve
and LS valve.
4. This linear motion is transmitted to rocker cam (4).
5. Being supported by ball retainer (10) on case (2), rocker
cam (4) moves rotationally.

PC45MR-5, PC55MR-5 10-65

COMPONENT PARTS OF HYDRAULIC SYSTEM 10 STRUCTURE AND FUNCTION

MAIN PUMP SERVO VALVE

STRUCTURE OF MAIN PUMP SERVO VALVE
General view and sectional view

GH: Swing and blade pump Hi signal port PLS: LS pressure input port
GL: Swing and blade pump Lo signal port PH: Pump shuttle pressure port
PAVE: Pump average pressure input port PM: PC mode selector pressure input port
PDE: EPC drain port P1L: Pump pressure input port
PE: Control piston pressure port T: Drain port
PEPC: EPC source pressure input port

10-66 PC45MR-5, PC55MR-5

10 STRUCTURE AND FUNCTION COMPONENT PARTS OF HYDRAULIC SYSTEM

1: Lever 10: Lock nut

2: Spool 11: Spring (LS valve)
3: Plug 12: PC-EPC valve
4: Sheet 13: Spool
5: Piston 14: Ball
6: Sleeve 15: Plug
7: PC valve 16: PC mode selector power supply connector
8: LS valve 17: Spring (PC valve)
9: Plug 18: Retainer

OPERATION OF MAIN PUMP SERVO VALVE

Action of spring
1. The spring force of spring (2) in PC valve is determined by the position of the swash plate.
2. If servo piston (6) moves to the right, spring (2) is compressed through lever (1), and the spring force
changes. The spring has characteristics that the spring constant changes into 2 stages depending on the
height of the spring.
Operation when pump pressure (PAVE) is low (load is light)

PC45MR-5, PC55MR-5 10-67

COMPONENT PARTS OF HYDRAULIC SYSTEM 10 STRUCTURE AND FUNCTION

1. The force of spool (4) decreases, and the position of the spool (3) is more to the right. The port (C) is con-
nected to port (D) at this time, and the pressure entering LS valve becomes drain pressure (PT).
2. The servo piston (6) moves to the left when port (F) is connected to port (G) of the LS valve, and the pres-
sure in port (J) becomes drain pressure (PT).
3. Pump discharged volume increases.
4. As servo piston (6) moves, lever (1) moves to the left, spring (2) expands, and the spring force is de-
creased.
Consequently, spool (3) moves to the left, port (C) is disconnected from port (D), and pump discharged
pressure (B) and (C) are connected.
5. Servo piston (6) stops moving to the left since the pressure in port (C) rises, and the piston pressure in-
creases.

Operation when pump pressure (PAVE) is high (load is heavy)

1. The force of spool (4) increases, and the position of the spool (3) is more to the left. Ports (B) and (C) are
connected at this time and the pressure entering LS valve becomes pump pressure (PP).
2. When port (F) is connected to port (G) of the LS valve, the pressure in port (J) becomes pump pressure
(PP), and servo piston (6) moves to the right.
3. The pump discharged volume is going to decrease.

10-68 PC45MR-5, PC55MR-5

10 STRUCTURE AND FUNCTION COMPONENT PARTS OF HYDRAULIC SYSTEM

4. As servo piston (6) moves, lever (1) moves to the right and spring (2) is compressed and spring force is
increased. Consequently, spool (3) moves to the right and port (C) is disconnected from port (B), and drain
pressure port (D) and port (C) are connected.
5. Servo piston (6) stops moving to the right since pressure in port (C) reduces, and the piston pressure de-
creases.
Operation when servo piston is stopped at balanced position

The stop position (or the pump discharged volume) of servo piston (6) is determined by the position where the
thrust caused by pump average pressure (PAVE) applied to spool (4) is balanced with the force of spring (2).
When swing and blade pump pressure increases or decreases
The stopping position of servo piston (6) is determined in the same way as the pressure applied to spool (4)
changes and pump average pressure (PAVE) increases or decreases.
When the PC-EPC valve is operated
The stopping position of servo piston (6) is determined in the same way as the output pressure of PC-EPC valve
is changed by the signal current from the controller and the pressure applied to spool (5) changes and pump
average pressure (PAVE) increases or decreases.

PC45MR-5, PC55MR-5 10-69

COMPONENT PARTS OF HYDRAULIC SYSTEM 10 STRUCTURE AND FUNCTION

MAIN PUMP LS VALVE

LS
Abbreviation for Load Sensing

FUNCTION OF MAIN PUMP LS VALVE

• The LS (Load Sensing) valve controls the pump discharged volume according to the travel of the control
lever, or the flow demanded by the actuator.
• LS valve detects the demand flow by the actuator from differential pressure (∆PLS) between inlet pressure
(PPLS) and outlet pressure (PLS) of the control valve, and it controls pump discharged volume (Q). [(PPLS)
is called LS pump pressure, (PLS) the LS pressure, and (∆PLS) the LS differential pressure]
• In other words, it controls pump discharged volume (Q) so that pressure loss [= LS differential pressure
(∆PLS)] which occurs when the oil flows through the passage in control valve spool will be constant, and
the pump will be able to discharge the proper volume of oil as demanded by the actuator.
• Pump discharged pressure (PP), LS pump pressure
(PPLS), and LS pressure (PLS) are transmitted to LS
valve. The relationship between LS differential pressure
(∆PLS) and pump discharged volume (Q) changes as
shown in the figure below.

• The demanded flow of the actuator is always supplied in the range where the flow rate does not exceed the
maximum flow rate during the operation with fine control, the pump discharged volume when the engine is
running at low speed will be the same as that when the engine is running at high speed. When the engine is
running at low speed, the setting of LS differential pressure automatically decreases, and the discharged
volume decreases.
• LS valve detects the pressure difference between before and after the fixed orifice (metering orifice) of dis-
charging passage of swing and blade pump, and control the LS set pressure.
• The discharged volume of swing and blade pump decreases when the engine is running at low speed, and
the pressure difference between before and after the fixed orifice (metering differential pressure (GH) -
(GL)) will be almost equal and low.
The discharged volume of swing and blade pump increases when the engine is running at high speed, and
metering differential pressure (GH) - (GL) will be high.
• When metering differential pressure is high (the engine speed is high), LS set pressure is set to higher val-
ue. When metering differential pressure (GH) - (GL) is low (the engine speed is low), LS set pressure is set
to lower value.
• The pump pressure (P1L), LS pressure (PLS), and the dif-
ferential pressure before and after the swing and blade
pump (metering differential pressure (GH) - (GL)) are
sent.The relationship between LS differential pressure
(∆PLS) and pump discharged volume (Q) varies as shown
in the following figure.

10-70 PC45MR-5, PC55MR-5

10 STRUCTURE AND FUNCTION COMPONENT PARTS OF HYDRAULIC SYSTEM

MAIN PUMP PC VALVE

PC
Abbreviation for Pressure Compensation

FUNCTION OF MAIN PUMP PC VALVE

• PC valve controls the equal horse power so that the horse-
power absorbed by the pump does not exceed the engine
horsepower, and the oil flow does not exceed a certain lev-
el (depending on the discharged pressure) even if the trav-
el of the control valve is increased extremely when pump
discharged pressure (PP) is high.
• When the pump discharged pressure increases due to in-
creased load during operation, this valve decreases the
pump discharged volume.
• When the pump discharged pressure decreases, this valve
increases the pump discharged volume.
• This pump has 2 discharge ports, and it senses the aver-
age of respective discharged pressures (P1) and (P2)
• The average of (P1) and (P2) is called (PAVE), and the relation between this average pressure pump dis-
charged volume the pump discharged volume [total discharge of this average pressure pump discharged
volume (P1) and (P2)] is as shown in the figure below.

PC45MR-5, PC55MR-5 10-71

COMPONENT PARTS OF HYDRAULIC SYSTEM 10 STRUCTURE AND FUNCTION

CONTROL VALVE
STRUCTURE OF CONTROL VALVE
General view
9-spool valve
REMARK
• They can be added and removed one by one at any time since the service valves are single add-on type.
• The service valve can be added between the upper cover and the valve under it.

10-72 PC45MR-5, PC55MR-5

10 STRUCTURE AND FUNCTION COMPONENT PARTS OF HYDRAULIC SYSTEM

A1: To L.H. travel motor A5: To bucket cylinder head

A2: To R.H. travel motor A6: To boom swing cylinder head
A3: To boom cylinder head A7: To blade cylinder head
A4: To arm cylinder head A8: To swing motor port (MA)

PC45MR-5, PC55MR-5 10-73

COMPONENT PARTS OF HYDRAULIC SYSTEM 10 STRUCTURE AND FUNCTION

A9: To stop valve PA9: From attachment PPC valve

B1: To L.H. travel motor PB1: From L.H. travel REVERSE PPC valve
B2: To R.H. travel motor PB2: From R.H. travel REVERSE PPC valve
B3: To boom cylinder bottom PB3: From boom RAISE PPC valve
B4: To arm cylinder bottom PB4: From arm IN PPC valve
B5: To bucket cylinder bottom PB5: From bucket CURL PPC valve
B6: To boom swing cylinder bottom PB6: From boom swing LEFT PPC valve
B7: To blade cylinder bottom PB7: From blade LOWER PPC valve
B8: To swing motor port (MB) PB8: From swing LEFT PPC valve
B9: To stop valve PB9: From attachment PPC valve
C: To hydraulic oil cooler PP: To pump LS valve
LS: To pump LS valve PP1: P1 pump pressure pickup port
P1: From main pump (variable pump) PP2: P2 pump pressure pickup port
P2: From main pump (variable pump) PP3: Pressure pickup port on work equipment side
P3: From main pump (Swing and blade pump) PLS1: L.H. travel LS pressure pickup port
PA1: From L.H. travel forward PPC valve PLS2: R.H. travel LS pressure pickup port
PA2: From R.H. travel forward PPC valve PLS3: Work equipment LS pressure pickup port
PA3: From boom LOWER PPC valve PTR: To auto-decelerator travel sensor port
PA4: From arm OUT PPC valve PW: To auto-decelerator work equipment sensor port
PA5: From bucket DUMP PPC valve PS: To swing motor B port
PA6: From boom swing RIGHT PPC valve S: To swing motor S port
PA7: From blade RAISE PPC valve T: To hydraulic tank
PA8: From swing RIGHT PPC valve TS: To hydraulic tank

10-74 PC45MR-5, PC55MR-5

10 STRUCTURE AND FUNCTION COMPONENT PARTS OF HYDRAULIC SYSTEM

Sectional views (A-A, B-B)

1: Suction valve (left travel) 4: Suction valve (arm bottom)

2: Suction valve (right travel) 5: Suction valve (bucket bottom)
3: Suction valve (boom bottom) 6: Suction valve (blade bottom)

PC45MR-5, PC55MR-5 10-75

COMPONENT PARTS OF HYDRAULIC SYSTEM 10 STRUCTURE AND FUNCTION

7: Port relief valve 18: Spool (right travel)

8: Safety valve 19: Unload valve
9: Suction valve (blade head) 20: Spool (boom)
10: Suction valve (boom swing head) 21: Spool (arm)
11: Suction valve (bucket head) 22: Spool (bucket)
12: Suction valve (arm head) 23. Spool (boom swing)
13: Suction valve (boom head) 24: Spool (blade)
14: Main relief valve 25: Spool (swing)
15: Suction valve (right travel) 26: Spool (attachment)
16: Suction valve (left travel) 27: Unload valve
17: Spool (left travel)

10-76 PC45MR-5, PC55MR-5

10 STRUCTURE AND FUNCTION COMPONENT PARTS OF HYDRAULIC SYSTEM

Sectional views (C-C, D-D, E-E)

1: Lift check valve 8: Pressure compensation valve (*1) (boom swing)

2: Pressure compensation valve (*1) (left travel) 9: Pressure compensation valve (*1) (attachment)
3: Pressure compensation valve (*1) (right travel) 10: Pressure compensation valve (*2) (attachment)
4: Spool (merge-divider valve) 11: Swing and blade pump relief valve
5: Pressure compensation valve (*1) (boom) 12: Pressure compensation valve (*2) (boom swing)
6: Pressure compensation valve (*1) (arm) 13: Pressure compensation valve (*2) (bucket)
7: Pressure compensation valve (*1) (bucket) 14: Pressure compensation valve (*2) (arm)

PC45MR-5, PC55MR-5 10-77

COMPONENT PARTS OF HYDRAULIC SYSTEM 10 STRUCTURE AND FUNCTION

15: Pressure compensation valve (*2) (boom) 20: Pilot pressure check valve
16: LS bypass plug 21: Spool (left travel)
17: Pressure compensation valve (*2) (right travel) 22: Suction valve (left travel)
18: Pressure compensation valve (*2) (left travel) 23: Suction valve (right travel)
19: Hydraulic oil cooler bypass valve
*1: Flow control valve
*2: Pressure reducing valve

10-78 PC45MR-5, PC55MR-5

10 STRUCTURE AND FUNCTION COMPONENT PARTS OF HYDRAULIC SYSTEM

Sectional views (F-F, G-G, H-H, J-J, AK-AK, AN-AN)

R.H. travel valve

1: Pressure compensation valve (*2) (right travel)

PC45MR-5, PC55MR-5 10-79

COMPONENT PARTS OF HYDRAULIC SYSTEM 10 STRUCTURE AND FUNCTION

2: Pressure compensation valve (*1) (right travel)

3: Spool (right travel)
4: Pilot pressure check valve
5: Suction valve
6: Suction valve
Unload valve
7: Unload valve
8: Check valve
9: Main relief valve
10: Unload valve
11: LS bypass plug
Unload valve and merge-divider valve
12: Spool (merge-divider valve)
13: Unload valve
14: Check valve
15: Unload valve
Boom valve
16: Pressure compensation valve (*1) (boom)
17: Spool (boom)
18: Pilot pressure check valve
19: Suction valve
20: Boom hydraulic drift prevention valve
21: Check valve
22: Check valve
23: Suction valve
24: Pressure compensation valve (*2) (boom)
*1: Flow control valve
*2: Pressure reducing valve

10-80 PC45MR-5, PC55MR-5

10 STRUCTURE AND FUNCTION COMPONENT PARTS OF HYDRAULIC SYSTEM

Sectional views (K-K, L-L, M-M, N-N, AA-AA, AB-AB)

Arm valve
1: Pressure compensation valve (*1) (arm)

PC45MR-5, PC55MR-5 10-81

COMPONENT PARTS OF HYDRAULIC SYSTEM 10 STRUCTURE AND FUNCTION

2: Spool (arm)
3: Pilot pressure check valve
4: Suction valve
5: Check valve
6: Suction valve
7: Pressure compensation valve (*2) (arm)
Bucket valve
8: Pressure compensation valve (*1) (bucket)
9: Spool (bucket)
10: Pilot pressure check valve
11: Suction valve
12: Check valve
13: Suction valve
14: Pressure compensation valve (*2) (bucket)
Boom swing valve
15: Pressure compensation valve (*1) (boom swing)
16. Spool (boom swing)
17: Pilot pressure check valve
18: Check valve
19: Suction valve
20: Pressure compensation valve (*2) (boom swing)
Blade valve
21: Spool (blade)
22: Pilot pressure shuttle valve
23: Suction valve
24: Check valve
Swing valve
25: Spool (swing)
26: Swing and blade pump relief valve
27: Safety valve
28: Pressure relief plug
*1: Flow control valve
*2: Pressure reducing valve
General view
10-spool valve
REMARK
The shapes of parts of 10-spool valve, except cross section AC-AC, are the same as that of 9-spool valve.

10-82 PC45MR-5, PC55MR-5

10 STRUCTURE AND FUNCTION COMPONENT PARTS OF HYDRAULIC SYSTEM

A10: To angle selector valve. PA10: From power angle PPC valve
B10: To angle selector valve. PB10: From power angle PPC valve
1: Pressure compensation valve (*1) (power angle) 4: Suction valve
2: Pressure compensation valve (*2) (power angle) 5: Pilot pressure check valve
3: Spool (power angle)
*1: Flow control valve
*2: Pressure reducing valve

PC45MR-5, PC55MR-5 10-83

COMPONENT PARTS OF HYDRAULIC SYSTEM 10 STRUCTURE AND FUNCTION

HYDRAULIC CIRCUIT DIAGRAMS OF CONTROL VALVE AND NAMES OF

VALVES
9-spool valve

10-84 PC45MR-5, PC55MR-5

10 STRUCTURE AND FUNCTION COMPONENT PARTS OF HYDRAULIC SYSTEM

1: L.H. travel valve Set pressure: LS pressure + 2.94 MPa {30 kg/cm2}

2: R.H. travel valve 22: Safety valve
3: Merge-divider valve Set pressure: 28.9 MPa {295 kg/cm2}
4: Boom valve 23: Main relief valve
5: Arm valve Set pressure: 26.5 MPa {270 kg/cm2}
6: Bucket valve 24: Logic valve
7: Boom swing valve 25: Pressure compensation valve
8: Blade valve 26: Suction valve
9: Swing valve 27: Check valve
10: Attachment valve 28: Pilot pressure check valve
11: L.H. travel valve spool 29: Pilot pressure shuttle valve
12: R.H. travel valve spool 30: Back pressure check valve
13: Merge-divider valve spool Set pressure: 0.37 MPa {3.8 kg/cm2}
14: Boom valve spool 31: Hydraulic oil cooler bypass valve
15: Arm valve spool Set pressure: 0.75 MPa {7.6 kg/cm2}
16: Bucket valve spool 32: Swing and blade pump relief valve
17: Boom swing valve spool Set pressure: 21.6 MPa {220 kg/cm2}
18: Blade valve spool 33: Boom lock valve
19: Swing valve spool 34: Port relief valve
20: Attachment valve spool Set pressure: 20.5 MPa {210 kg/cm2}
21: Unload valve
10-spool valve
REMARK
The hydraulic circuit diagram of 10-spool valve shows only the portions different from the 9-pool valve are
shown.

PC45MR-5, PC55MR-5 10-85

COMPONENT PARTS OF HYDRAULIC SYSTEM 10 STRUCTURE AND FUNCTION

1: Power angle valve 4: Pilot pressure check valve

2: Power angle valve spool 5: Port relief valve
3: Pressure compensation valve Set pressure: 20.6 MPa {210 kg/cm2}

10-86 PC45MR-5, PC55MR-5

10 STRUCTURE AND FUNCTION COMPONENT PARTS OF HYDRAULIC SYSTEM

UNLOAD VALVE OF CONTROL VALVE

FUNCTION OF UNLOAD VALVE OF CONTROL VALVE
When the work equipment is held

• This valve releases discharged volume (Q) into the tank circuit corresponding to the swash plate at mini-
mum angle when the work equipment is held (the control valve is in neutral).
• Pump discharged pressures (P1) and (P2) are set by the reaction force of spring (2) in the valve.
• The pressure in LS circuit (PLS) is 0 MPa {0 kg/cm2} since the control valve is in neutral.

PC45MR-5, PC55MR-5 10-87

COMPONENT PARTS OF HYDRAULIC SYSTEM 10 STRUCTURE AND FUNCTION

When the work equipment is operated with fine control

• Pump discharged pressures (P1) and (P2) are set to be equal to the sum of LS pressures (PLS1) and
(PLS2) and the pressure caused by reaction forced of spring (2) when the actuator demand flow is less
than the pump discharge at the minimum swash plate angle and the work equipment is operated with fine
control.
• The unload valve opens and LS differential pressure (∆PLS) becomes the set pressure of spring (2) when
the differential pressure between pump discharged pressures (P1) and (P2) and LS pressures (PLS1) and
(PLS2) reaches the set pressure of spring (2).

10-88 PC45MR-5, PC55MR-5

10 STRUCTURE AND FUNCTION COMPONENT PARTS OF HYDRAULIC SYSTEM

When the work equipment is operated

The unload valve blocks the oil flowing to tank circuit (T), and all of pump discharged volumes (Q1) and (Q2) are
returned to the actuator circuit when the actuator demand flow exceeds the pump discharge volume at the mini-
mum pump swash plate angle when the work equipment is operated.

PC45MR-5, PC55MR-5 10-89

COMPONENT PARTS OF HYDRAULIC SYSTEM 10 STRUCTURE AND FUNCTION

When only traveling is operated (L.H. and R.H.)

The pump swash plate angle becomes maximum, and the oil flow is controlled according to the opening of spool
(1) when only traveling is operated (L.H. and R.H.).

10-90 PC45MR-5, PC55MR-5

10 STRUCTURE AND FUNCTION COMPONENT PARTS OF HYDRAULIC SYSTEM

OPERATION OF UNLOAD VALVE OF CONTROL VALVE

When the work equipment is held

1. Pump discharged pressures of (P1) and (P2) act on the left side of spool (1), and LS pressures of (PLS1)
and (PLS2) act on the right side of the spool.
2. LS pressure [(PLS1) and (PLS2)] is 0 when the work equipment is held (control valve is held), and only
pump discharged pressures of (P1) and (P2) act. Pump discharged pressures of (P1) and (P2) are set only
by the spring load of spring (2).
3. The differential pressure between pump discharged pressure (P1) and LS pressure (PLS1) and the differ-
ential pressure between pump discharged pressure (P2) and LS pressure (PLS2) reach the set pressure of
spring (2).
4. Spool (1) moves to the right, and the pressurized oil flows from pump circuits (P1) and (P2) through notch
(a) of spool (1) into tank circuit (T).

PC45MR-5, PC55MR-5 10-91

COMPONENT PARTS OF HYDRAULIC SYSTEM 10 STRUCTURE AND FUNCTION

When operating the work equipment with fine control

1. When operating the work equipment with fine control, LS pressures of (PLS1) and (PLS2) are generated
and they act on the right side of spool (1).
2. The differential pressure between LS pressures of (PLS1) and (PLS2) and pump discharged pressures of
(P1) and (P2) is large since the open area of the control valve spool is small.
3. The differential pressure between pump discharged pressures of (P1) and (P2) and LS pressures of (PLS1)
and (PLS2) reaches the set pressure of spring (2).
4. Spool (1) moves to the right, and pump circuits (P1) and (P2) are connected to tank circuit (T).
5. Pump discharged pressures of (P1) and (P2) are set to the set pressure of spring (2) + LS pressures of
(PLS1) and (PLS2).
6. LS differential pressure (∆PLS) becomes the set pressure of spring (2).

10-92 PC45MR-5, PC55MR-5

10 STRUCTURE AND FUNCTION COMPONENT PARTS OF HYDRAULIC SYSTEM

When the work equipment is operated

1. When the work equipment is largely operated, LS pressures of (PLS1) and (PLS2) are generated, and they
act on the right side of spool (1).
2. The differential pressure between LS pressures of (PLS1) and (PLS2) and pump discharged pressures of
(P1) and (P2) is small since the open area of the control valve spool is large.
3. The differential pressure between pump discharged pressures of (P1) and (P2) and LS pressures of
(PLS1), (PLS2) does not reach the set pressure of spring (2).
4. Spool (1) is pushed to the left by spring (2).
5. Pump circuits (P1) and (P2) are disconnected from tank circuit (T), and all the pump discharged volumes
(Q1) and (Q2) flow to the actuator circuit.

PC45MR-5, PC55MR-5 10-93

COMPONENT PARTS OF HYDRAULIC SYSTEM 10 STRUCTURE AND FUNCTION

When only traveling is operated (L.H. and R.H.)

1. When only traveling is operated (L.H. and R.H.), the merge-divider valve divides the main pump discharged
volume.
2. Each unload valve of pump circuits (P1) and (P2) operates according to the open areas of each travel spool
(1) on the right and left sides.

10-94 PC45MR-5, PC55MR-5

10 STRUCTURE AND FUNCTION COMPONENT PARTS OF HYDRAULIC SYSTEM

PRESSURE COMPENSATION VALVE OF CONTROL VALVE

FUNCTION OF PRESSURE COMPENSATION VALVE OF CONTROL VALVE

When the load pressure becomes lower than another actuator and the flow is going to increase during a com-
bined operation, this valve compensates the load pressure. (At this time, the load pressure of another actuator
under combined operation (the right side) is higher than that of the actuator on this side (the left side).)

PC45MR-5, PC55MR-5 10-95

COMPONENT PARTS OF HYDRAULIC SYSTEM 10 STRUCTURE AND FUNCTION

OPERATION OF PRESSURE COMPENSATION VALVE OF CONTROL VALVE

1. When the load pressure of the other actuator (right side) increases during combined operation, the flow to
the actuator circuit (A) on this side (left side) is going to increase.
2. In this case, LS pressure (PLS) of another actuator acts to spring chamber (PLS'), it pushes pressure re-
ducing valve (1) and flow control valve (2) to the left.
3. Flow control valve (2) reduces the open area between pump circuit (PP) and spool upstream (PPA) to gen-
erate a pressure loss between (PP) and (PPA).
4. The flow control valve (2) and the pressure reducing valve (1) balance each other out at the place where
the pressure difference between (PA) and (PLS) which applies to the both end surfaces of the pressure re-
ducing valve (1) becomes the same as the pressure loss between (PP) and (PPA) around the flow control
valve.
5. The pressure difference between upstream pressure (PPA) and downstream pressure (PA) of both spools
which is operating the combined operation becomes the same, and pump discharge is divided in proportion
to the opening of each spool notch (a).

10-96 PC45MR-5, PC55MR-5

10 STRUCTURE AND FUNCTION COMPONENT PARTS OF HYDRAULIC SYSTEM

SURFACE AREA RATIO OF PRESSURE COMPENSATION VALVE OF CONTROL

VALVE
FUNCTION OF SURFACE AREA RATIO OF PRESSURE COMPENSATION VALVE
OF CONTROL VALVE

Function
The pressure compensation valve finely adjusts the surface area ratio (S1:S2) to determine the compensation
characteristics according to the characteristics of each actuator. (S1) is the surface area on the left side of flow
control valve (2), and (S2) is the surface area on the right side of pressure reducing valve (1).
Ratio of pressures acting on areas (S1) and (S2) and compensation characteris-
tics
• The flow rate from the pump is divided in proportion to the open area of notch (a) of spool (3) when the
pressure loss between pump discharged pressure (PP) and upstream pressure of spool notch (PPA) is al-
most equal to the pressure difference between LS circuit pressure (PLS) and actuator circuit pressure (PA)
(namely the pressure in port (A)) (the pressure ratio is 1.00).
• The flow from the pump is less supplied to the compensated side when the pressure loss between pump
discharged pressure (PP) and upstream pressure of spool notch (PPA) is larger than the pressure differ-
ence between LS circuit pressure (PLS) and actuator circuit pressure (PA) (namely the pressure in port (A))

PC45MR-5, PC55MR-5 10-97

COMPONENT PARTS OF HYDRAULIC SYSTEM 10 STRUCTURE AND FUNCTION

(the pressure ratio is 1.00 or higher), the open area of the pressure compensation valve on the
compensating side increases.
• The flow from the pump is more supplied to the compensated side when the pressure loss between pump
discharged pressure (PP) and upstream pressure of spool notch (PPA) is smaller than the pressure differ-
ence between LS circuit pressure (PLS) and actuator circuit pressure (PA) (namely the pressure in port (A))
(the pressure ratio is 1.00 or lower), the open area of the pressure compensation valve on the compensat-
ing side decreases.

LS INTRODUCTION THROTTLE OF PRESSURE COMPENSATION VALVE OF

CONTROL VALVE
FUNCTION OF LS INTRODUCTION THROTTLE OF PRESSURE COMPENSATION
VALVE OF CONTROL VALVE

This function divides the pressurized oil from LS introduction throttle (b) of reducing valve (1) in order to supply
more oil to the compensated side when another actuator is relieved during combined operations.

10-98 PC45MR-5, PC55MR-5

10 STRUCTURE AND FUNCTION COMPONENT PARTS OF HYDRAULIC SYSTEM

OPERATION OF LS INTRODUCTION THROTTLE OF PRESSURE COMPENSA-

TION VALVE OF CONTROL VALVE

1. If another actuator (right side) is relieved during combined operations, circuit pressures (PPA) and (PA) of
another actuator will be the same as the pump circuit pressure [(PP) = relief pressure].
2. The pressure of spring chamber (PLSA) of the other actuator will be the same as the pump circuit pressure
(PP) by reducing valve (1) set in neutral.
3. The pressure of spring chamber (PLSB) passes through LS introduction throttle (b) of reducing valve (1),
and it becomes (PLS).
4. The LS pressure (PLS) is connected to tank circuit (T) from LS bypass plug (4), and the pressure loss oc-
curs at LS introduction throttle (b) ((PLS) < (PLSB)).
5. Even when another actuator is relieved, a pressure difference is generated between (PP) and (PLS), so
more oil flows from actuator circuit (A) on this side (left side).

INTRODUCTION OF LS PRESSURE IN CONTROL VALVE

LS
Abbreviation for Load Sensing

PC45MR-5, PC55MR-5 10-99

COMPONENT PARTS OF HYDRAULIC SYSTEM 10 STRUCTURE AND FUNCTION

FUNCTION OF INTRODUCTION OF LS PRESSURE IN CONTROL VALVE

• LS pressure is the actuator load pressure on the outlet side of the control valve.
• Pump discharged pressure (PP3) is reduced to the same pressure as that of actuator circuit (A) at pressure
reducing valve (3) of pressure compensation valve, and it is introduced to LS circuit (PLS).

10-100 PC45MR-5, PC55MR-5

10 STRUCTURE AND FUNCTION COMPONENT PARTS OF HYDRAULIC SYSTEM

OPERATION OF INTRODUCTION OF LS PRESSURE IN CONTROL VALVE

1. Pump discharged pressure (PP3) flows through flow control valve (2), notch (a) in the spool, and bridge
passage (b) to actuator circuit (A) when spool (1) is operated.
2. Pressure reducing valve (3) moves to the right at this time, pump discharged pressure (PP3) is reduced by
pressure loss at notch (c), and sent to LS circuit (PLS3). Then, it is sent to spring chamber (PLS').
3. LS circuit (PLS) is connected from LS bypass plug (4) to tank circuit (T). (See “LS BYPASS PLUG OF
CONTROL VALVE”.)
4. Actuator circuit pressure (A) acts on the left side of pressure reducing valve (3). The reduced pump dis-
charged pressure (PP3) acts on the opposite side.
5. Pressure reducing valve (3) is balanced out at a position where actuator circuit pressure (A) and the pres-
sure of spring chamber (PLS') are the same. Pump discharged pressure (PP3) reduced at notch (a) be-
comes actuator circuit pressure (A), and is transmitted into LS circuit (PLS3).

LS BYPASS PLUG OF CONTROL VALVE

LS
Abbreviation for Load Sensing

FUNCTION OF LS BYPASS PLUG OF CONTROL VALVE

• It releases the remaining pressure of LS pressure (PLS).

PC45MR-5, PC55MR-5 10-101

COMPONENT PARTS OF HYDRAULIC SYSTEM 10 STRUCTURE AND FUNCTION

• While it moderates the increasing rate of LS pressure (PLS), this valve generates pressure loss in the throt-
tle part of the spool and shuttle valve with this discarded throttle flow, decreasing the enabled LS differential
pressure and improving stability.

OPERATION OF LS BYPASS PLUG OF CONTROL VALVE

The pressurized oil flows from LS circuit through filter (a) and orifice (b) to the tank circuit.

10-102 PC45MR-5, PC55MR-5

10 STRUCTURE AND FUNCTION COMPONENT PARTS OF HYDRAULIC SYSTEM

LOGIC VALVE OF CONTROL VALVE

FUNCTION OF LOGIC VALVE OF CONTROL VALVE

The logic valve changes the pilot pressure in order to switch the merge-divider valve.

PC45MR-5, PC55MR-5 10-103

COMPONENT PARTS OF HYDRAULIC SYSTEM 10 STRUCTURE AND FUNCTION

OPERATION OF LOGIC VALVE OF CONTROL VALVE

Operation in dividing mode

1. Only travel PPC pressure acts on port (b).
2. Travel PPC pressure acts on output port (c) of the merge-divider valve as it is.
3. This pressure sets the merge-divider valve to the dividing mode.
Operation in merging mode
1. Work equipment PPC pressure (excluding the swing pressure) acts on port (a).
2. The pressure in output port (c) of the merge-divider valve is connected through spool (1) to spring chamber
(d) and used as seal drain pressure.
3. The merge-divider valve is not changed but kept in the merging mode.
REMARK
Even if travel PPC pressure acts while work equipment PPC pressure (excluding the swing pressure) is acting,
spool (1) is kept pressed and the merge-divider valve is kept in the merging mode.

10-104 PC45MR-5, PC55MR-5

10 STRUCTURE AND FUNCTION COMPONENT PARTS OF HYDRAULIC SYSTEM

MERGE-DIVIDER VALVE OF CONTROL VALVE

FUNCTION OF MERGE-DIVIDER VALVE OF CONTROL VALVE
When traveling with only one side of tracks is operated

The merge-divider valve spool separates pump discharged pressures (P1) and (P2) when traveling with only
one side of tracks is operated.

PC45MR-5, PC55MR-5 10-105

COMPONENT PARTS OF HYDRAULIC SYSTEM 10 STRUCTURE AND FUNCTION

When the work equipment is operated, or when the work equipment is operated
during traveling

When the work equipment is operated, or when the work equipment is operated during traveling, the merge-
divider valve spool merges pump discharged pressures (P1) and (P2).

10-106 PC45MR-5, PC55MR-5

10 STRUCTURE AND FUNCTION COMPONENT PARTS OF HYDRAULIC SYSTEM

OPERATION OF MERGE-DIVIDER VALVE OF CONTROL VALVE

Operation when traveling with only one side of tracks is operated

1. When traveling with only one side of tracks is operated, the travel PPC pressure acts on the right side of
merge-divider valve spool (1) through the logic valve spool.
2. When the travel PPC pressure is larger than the reaction force of spring (2), merge-divider valve (1) is
pushed to the left.
3. Pump pressures (P1), (P2), and (P3) are separated from LS pressures (PLS1), (PLS2), and (PLS3).
4. The pump pressure is outputted to output pressure (PLS) which is applied to pump LS valve.

PC45MR-5, PC55MR-5 10-107

COMPONENT PARTS OF HYDRAULIC SYSTEM 10 STRUCTURE AND FUNCTION

Operation when the work equipment is operated, or when the work equipment is
operated during traveling

Operation when the work equipment is operated

1. When the work equipment is operated, the output from the logic valve spool is used as seal drain pressure.
2. The pressure for switching the merge-divider valve is drained to the tank.
3. Merge-divider valve spool (1) is pressed to the right by the force of spring (2).
4. Pump pressures (P1), (P2), and (P3) are merged with LS pressures (PLS1), (PLS2), and (PLS3).
Operation when the work equipment is operated during traveling
1. When the work equipment is operated during traveling, the logic valve spool is switched.
2. The travel PPC pressure is not applied to the merge-divider valve.
3. Since the pressure for switching the merge-divider valve is drained into the tank, they are merged.
4. When the work equipment is in neutral, they are merged since the spring force of the merge-divider valve
spool is larger than the pressure for shifting the travel PPC pressure.

10-108 PC45MR-5, PC55MR-5

10 STRUCTURE AND FUNCTION COMPONENT PARTS OF HYDRAULIC SYSTEM

TRAVEL JUNCTION VALVE OF CONTROL VALVE

FUNCTION OF TRAVEL JUNCTION VALVE OF CONTROL VALVE
When the machine travels straight

• The travel junction circuit is installed so that the flow difference between R.H. and L.H. travel circuits is cor-
rected when the machine travels straight.
• This function reduces travel deviation by making the flows to the right and left travel motors almost equal
when the machine travels straight.
• Damper (b) is installed to ease the transient characteristics of sudden opening and closing of the intercon-
nection circuit when the travel control lever is operated quickly.

PC45MR-5, PC55MR-5 10-109

COMPONENT PARTS OF HYDRAULIC SYSTEM 10 STRUCTURE AND FUNCTION

OPERATION OF TRAVEL JUNCTION VALVE OF CONTROL VALVE

When the machine is traveling straight

1. Bridge circuits (PA) of the control valves of R.H. and L.H. travel circuits are connected to each other by
junction circuit (L).
2. This valve corrects the difference between the oil flow rates in R.H. and L.H. travel motors to reduce the
travel deviation.

10-110 PC45MR-5, PC55MR-5

10 STRUCTURE AND FUNCTION COMPONENT PARTS OF HYDRAULIC SYSTEM

When the machine is turning by steering operation

1. When R.H. travel spool (right 1) is returned to neutral from the straight-travel state and the steering opera-
tion is performed, the load pressure difference “(left A) > (right A)” is made between R.H. and L.H. actuator
circuits (PA).
2. The discharged pressure of main pump is divided at this time.
3. The flow rate of oil flowing into R.H. and L.H. travel motors changes corresponding to the opening area of
the spool.

PC45MR-5, PC55MR-5 10-111

COMPONENT PARTS OF HYDRAULIC SYSTEM 10 STRUCTURE AND FUNCTION

SWING AND BLADE VALVE OF CONTROL VALVE

STRUCTURE OF SWING AND BLADE VALVE OF CONTROL VALVE

• The swing and blade valves are the open center valves of the swing and blade pump. The blade valves are
arranged in tandem after the swing valve.
• Load check valve (2) is installed in each spool. These are corresponding to ports (A7), (B7), (A8), and (B8)
of valves.
• Relief valve(1) for the swing and blade pump is installed to the swing valve.

10-112 PC45MR-5, PC55MR-5

10 STRUCTURE AND FUNCTION COMPONENT PARTS OF HYDRAULIC SYSTEM

OPERATION OF SWING AND BLADE VALVE OF CONTROL VALVE

Swing valve
1. If pressure from PPC valve is applied to port (PA8), the spool moves to the left and oil flows into port (A8).
2. If pressure from PPC valve is applied to port (PB8), the spool moves to the right and oil flows into port (B8).
Blade valve
1. If pressure from PPC valve is applied to port (PA7), the spool moves to the left and oil flows into port (A7).
2. If pressure from PPC valve is applied to port (PB7), the spool moves to the right and oil flows into port (B7).

PC45MR-5, PC55MR-5 10-113

COMPONENT PARTS OF HYDRAULIC SYSTEM 10 STRUCTURE AND FUNCTION

SWING PARKING BRAKE CANCEL CIRCUIT OF CONTROL VALVE

OPERATION OF SWING PARKING BRAKE CANCEL CIRCUIT OF CONTROL
VALVE

1. The left and right swing PPC pressures and the arm IN PPC pressure pass through the check valve in the
spring case, and the highest one of them is outputted from port (PS) to swing motor port (BR).
2. The arm and swing control valves are connected by the pilot passage inside the control valve.

10-114 PC45MR-5, PC55MR-5

10 STRUCTURE AND FUNCTION COMPONENT PARTS OF HYDRAULIC SYSTEM

WORK EQUIPMENT PILOT PRESSURE DETECTION CIRCUIT OF CONTROL

VALVE
FUNCTION OF WORK EQUIPMENT PILOT PRESSURE DETECTION CIRCUIT OF
CONTROL VALVE
This circuit collects the pilot pressures of the work equipment (excluding the swing operation), and outputs oil
pressure signals through the auto-deceleration sensor port.

OPERATION OF WORK EQUIPMENT PILOT PRESSURE DETECTION CIRCUIT

OF CONTROL VALVE

PC45MR-5, PC55MR-5 10-115

COMPONENT PARTS OF HYDRAULIC SYSTEM 10 STRUCTURE AND FUNCTION

When the work equipment is operated, the pilot pressures of the boom, arm, bucket, boom swing, blade, and
attachment are outputted to auto-deceleration sensor port (PW) through the check valves and shuttle valves in
their respective spring cases.

TRAVEL PILOT PRESSURE DETECTION CIRCUIT OF CONTROL VALVE

FUNCTION OF TRAVEL PILOT PRESSURE DETECTION CIRCUIT OF CONTROL
VALVE
This circuits collects the pilot pressures for R.H. travel and L.H. travel, and outputs oil pressure signals through
the auto-deceleration sensor port.

OPERATION OF TRAVEL PILOT PRESSURE DETECTION CIRCUIT OF CONTROL

VALVE

10-116 PC45MR-5, PC55MR-5

10 STRUCTURE AND FUNCTION COMPONENT PARTS OF HYDRAULIC SYSTEM

When the machine travels, R.H. and L.H. travel PPC pressures are outputted to auto-deceleration sensor port
(PTR) through the check valves in their respective spring cases.

PC45MR-5, PC55MR-5 10-117

LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM 10 STRUCTURE AND FUNCTION

WORK EQUIPMENT SYSTEM

LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM
Chassis part

1: Arm cylinder 5: Multi-control valve (*1)

2: Boom cylinder 6: Bipartite solenoid valve
3: Boom swing cylinder 7: Blade cylinder
4: Pilot circuit accumulator 8: Bucket cylinder
*1: Optional device.

10-118 PC45MR-5, PC55MR-5

10 STRUCTURE AND FUNCTION LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM

9: Control valve 11: Work equipment PPC pressure switch

10: Swing parking brake pressure sensor 12: Travel PPC pressure sensor

PC45MR-5, PC55MR-5 10-119

LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM 10 STRUCTURE AND FUNCTION

Around cab and floor

1: Blade PPC valve 7: Lock lever

2. R.H. work equipment PPC valve 8: Attachment PPC valve (*2)
3: Starting switch 9: Boom swing PPC valve
4: L.H. work equipment PPC valve 10: 1st-line attachment proportional switch (*3)
5: Machine controller 11: Breaker operating switch (*3)
6: PPC lock switch
*2: Machine with attachment
*3: Machine with proportional lever

10-120 PC45MR-5, PC55MR-5

10 STRUCTURE AND FUNCTION LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM

12: Lock lever automatic lock switch

PC45MR-5, PC55MR-5 10-121

STRUCTURE OF VALVE CONTROL 10 STRUCTURE AND FUNCTION

STRUCTURE OF VALVE CONTROL

1: R.H. work equipment control lever (for operation of 8: Attachment PPC valve (*1)
boom and bucket) 9: Bipartite solenoid valve
2. R.H. work equipment PPC valve 10: Travel PPC valve
3: L.H. work equipment control lever (for operation of 11: Travel pedal
arm and swing)
12: Boom swing PPC valve
4: L.H. work equipment PPC valve
13: R.H. travel lever
5: Lock lever
14: L.H. travel lever
6: Accumulator (for PPC circuit)
7: Control valve
*1: Machine with attachment

10-122 PC45MR-5, PC55MR-5

10 STRUCTURE AND FUNCTION STRUCTURE OF VALVE CONTROL

15: Blade control lever 17: Boom swing control pedal

16: Blade PPC valve

PC45MR-5, PC55MR-5 10-123

PPC LOCK SYSTEM 10 STRUCTURE AND FUNCTION

PPC LOCK SYSTEM

PPC
Abbreviation for Proportional Pressure Control

PPC LOCK SYSTEM DIAGRAM

Input and output signals

a: PPC lock signal g: Breaker operating switch signal
b: PPC lock signal h: Oil pressure sensor signal
c: Lock lever automatic lock cancel switch signal i: Oil pressure switch signal
d: Lock lever automatic lock relay drive signal j: 1st-line attachment flow adjustment EPC valve sig-
e: PPC lock solenoid valve drive signal nal
f: Switch potentiometer signal
1: Battery disconnect switch 11: Breaker operating switch
2: Battery 12: PPC lock solenoid valve
3: Fusible link 13: Control valve
4: Fuse box 13a: Merge-divider valve
5: Starting switch 14: Main pump
6: Lock lever 15: Lock lever automatic lock cancel switch
7: PPC lock switch 16: 1st-line attachment flow adjustment EPC valve
8: Machine controller 17: Swing motor
9: PPC lock lever relay 17a: Swing parking brake
10: 1st-line attachment proportional switch

10-124 PC45MR-5, PC55MR-5

10 STRUCTURE AND FUNCTION PPC LOCK SYSTEM

FUNCTION OF PPC LOCK SYSTEM

• PPC lock switch is interlocked with the lock lever. When the lock lever is set to LOCK position, PPC lock
switch is turned “OFF”.
• When PPC lock switch is turned OFF, the current flowing into PPC lock solenoid valve is cut out, and the
work equipment and machine body do not move even if any control lever or pedal is operated.

PC45MR-5, PC55MR-5 10-125

WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 10 STRUCTURE AND FUNCTION

WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM

FUNCTION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM
This function automatically sets the lock lever in the same state as when it is locked to prevent the work equip-
ment or the machine continues its operation when the lock lever is unlocked while the work equipment control
lever or the travel lever is operated.

OPERATION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM

This system recognizes an abnormality when either one or
more of the oil pressure switches or sensors detect the pres-
sure higher than specified pressure (D), or if the attachment
drive signal is input in time period (C) after the lock lever is
canceled (A).
The machine controller outputs the lock lever automatic lock re-
lay drive signal to shut off the current to PPC lock solenoid and
set the machine to lock state (B).
A: Lock lever is canceled
B: Lock lever automatic lock is in operation
C: Within 0.4 seconds
D: 5 kPa
E: 0.1 seconds
REMARK
The pressure may not increase within time (C) and the lock lever automatic lock control may not operate when
the hydraulic oil temperature is low or high-viscosity hydraulic oil used.
Control when lock lever automatic lock cancel switch is “ON”
you can operate the machine by operating lock lever automatic
lock cancel switch (1) if an abnormality occurs in the controller,
etc., and the main pump does not operate normally, and ma-
chine does not work.
At this time, the lock lever automatic lock control function does
not work.
a: Emergency (when abnormal)
b: Normal (when normal)
REMARK
• Lock lever automatic lock cancel switch (1) is an alternate
type switch. The lock lever automatic lock cancel pilot lamp
lights up on the display if it is set to “EMERGENCY (a)” po-
sition when PPC lock lever is in the free state.
• The following failure code is displayed when this switch is
“ON”.
Action Failure
Failure (displayed on screen)
level code
DDNS0
L00 Lock Lever Auto Lock Release SW On
0

10-126 PC45MR-5, PC55MR-5

10 STRUCTURE AND FUNCTION OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT

OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT

(Machine with proportional lever)

ATTACHMENT OIL FLOW ADJUSTER SYSTEM DIAGRAM

Input and output signals

a: PC-EPC valve drive signal g: 1st-line attachment proportional switch signal
b: Solenoid valve GND h: Breaker control switch signal
c: CAN signal i: 1st throttle signal
d: CAN signal j: Fuel supply pump control signal
e: 1st-line attachment EPC drive signal k: Various sensor signals
f: 1st-line attachment EPC drive signal
1: Battery disconnect switch 14: 1st-line attachment proportional switch
2: Battery 15: Breaker operating switch
3: Fusible link 16: Main pump
4: Starting switch 16a: Servo
5: Fuse box 16b: LS valve
6: Resistor for PC-EPC valve 16c: PC valve
7: Machine controller 17: Control valve
8: Engine controller 17a: Merge-divider valve
9: Machine monitor 18: PPC lock solenoid valve
10: Pump secondary drive switch 19: 1st-line attachment flow adjustment EPC valve
11: Fuel control dial 20: 1st-line attachment flow adjustment EPC valve
12: Fuel supply pump 21: PC-EPC valve
13: Various sensors 22: Attachment circuit selector valve

PC45MR-5, PC55MR-5 10-127

OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT 10 STRUCTURE AND FUNCTION

23: Attachment

FUNCTION OF OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT

Operating the attachment proportional switch controls the flow rate to the attachment when mode ATT/P or
ATT/E is selected and the attachment flow is set with the machine monitor.

10-128 PC45MR-5, PC55MR-5

10 STRUCTURE AND FUNCTION COMPONENT PARTS OF WORK EQUIPMENT SYSTEM

COMPONENT PARTS OF WORK EQUIPMENT SYSTEM

WORK EQUIPMENT AND SWING PPC VALVE
PPC
Abbreviation for Proportional Pressure Control

STRUCTURE OF WORK EQUIPMENT AND SWING PPC VALVE

General view

PC45MR-5, PC55MR-5 10-129

COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 10 STRUCTURE AND FUNCTION

L.H. work equipment control lever

P: From pilot pump
P1: To control valve (arm IN port)
P2: To control valve (arm OUT port)
P3: To control valve (swing RIGHT port)
P4: To control valve (swing LEFT port)
T: To hydraulic tank
R.H. work equipment control lever
P: From pilot pump
P1: To control valve (boom RAISE port)
P2: To control valve (boom LOWER port)
P3: To control valve (bucket DUMP port)
P4: To control valve (bucket CURL port)
T: To hydraulic tank

10-130 PC45MR-5, PC55MR-5

10 STRUCTURE AND FUNCTION COMPONENT PARTS OF WORK EQUIPMENT SYSTEM

Sectional view

1: Spool 4: Nut (for connecting lever)

2: Piston 5: Joint
3: Disc 6: Plate

PC45MR-5, PC55MR-5 10-131

COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 10 STRUCTURE AND FUNCTION

7: Retainer 9: Filter
8: Body

OPERATION OF WORK EQUIPMENT AND SWING PPC VALVE

When it is in neutral
Ports (A) and (B) of the control valve and ports (P1) and P2) of
PPC valve are connected to drain chamber (D) through fine
control hole (f) of spool (1).

When operating with fine control(when fine control is started from neutral state)
1. When piston (4) is pushed by disc (5), retainer (9) is push-
ed, spool (1) is also pushed and moved down through me-
tering spring (2).
2. When fine control hole (f) is blocked from drain chamber
(D), it is connected to pump pressure chamber (PP) almost
at the same time.
3. The pilot pressure oil of the control pump flows to port (A)
through fine control hole (f) and port (P1).
4. When the pressure in port (P1) increases, spool (1) is
pushed back. When fine control hole (f) is disconnected
from pump pressure chamber (PP), it is connected to drain
chamber (D) almost at the same time, and the pressure in
port (P1) is released.
5. Spool (1) moves up and down so that the force of metering
spring (2) is balanced with the pressure in port (P1).
6. The positional relation between spool (1) and body (10)
(fine control hole (f) is at intermediate position between
drain chamber (D) and pump pressure chamber (PP))
does not change until retainer (9) touches spool (1).
7. Metering spring (2) is compressed in proportion to the trav-
el of control lever.
8. The pressure in port (P1) also increases in proportion to
the travel of control lever.

10-132 PC45MR-5, PC55MR-5

10 STRUCTURE AND FUNCTION COMPONENT PARTS OF WORK EQUIPMENT SYSTEM

9. The control valve spool moves to a position where the pressure in port (A) (which is the same as the pres-
sure in port (P1)) is balanced with the reaction force of the control valve spool return spring.
When operating with fine control(when control lever is returned)
1. When disc (5) starts being returned, spool (1) is pushed up
by the force of centering spring (3) and the pressure in port
(P1).
2. Fine control hole (f) is connected to drain chamber (D),
and the pressurized oil in port (P1) is released.
3. If the pressure in port (P1) decreases too much, spool (1)
is pushed down by metering spring (2).
4. When fine control hole (f) is disconnected from drain
chamber (D), it is connected to pump pressure chamber
(PP) almost at the same time.
5. The pump pressure is supplied until the pressure in port
(P1) recovers to the pressure corresponding to the lever
position.
6. When the spool of control valve returns, the pressurized oil
in drain chamber (D) flows in through fine control hole (f')
in the valve on the side that is not operated. The oil passes
through port (P2) and flows into chamber (B) to replenish
the port with pressurized oil.

When operating control lever fully

1. Disc (5) pushes down piston (4), and retainer (9) pushes
down spool (1).
2. Fine control hole (f) is disconnected from drain chamber
(D), and connected to pump pressure chamber (PP).
3. The pilot pressure oil from the solenoid valve flows from
port (P1) through fine control hole (f) to port (A), and push-
es the control valve spool.
4. The return oil from port (B) flows from port (P2) through
fine control hole (f) to drain chamber (D).

PC45MR-5, PC55MR-5 10-133

COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 10 STRUCTURE AND FUNCTION

ATTACHMENT PPC VALVE

(Machines with attachment)
PPC
Abbreviation for Proportional Pressure Control

STRUCTURE OF ATTACHMENT PPC VALVE

General view and sectional view

P: From pilot pump P2: To control valve (attachment port)

P1: To control valve (attachment port) T: To hydraulic tank

10-134 PC45MR-5, PC55MR-5

10 STRUCTURE AND FUNCTION COMPONENT PARTS OF WORK EQUIPMENT SYSTEM

1: Spool 5: Retainer
2: Piston 6: Body
3: Lever 7: Filter
4: Plate
REMARK
For explanation of operation, see “OPERATION OF WORK EQUIPMENT AND SWING PPC VALVE”.

PC45MR-5, PC55MR-5 10-135

COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 10 STRUCTURE AND FUNCTION

BLADE PPC VALVE

PPC
Abbreviation for Proportional Pressure Control

STRUCTURE OF BLADE PPC VALVE

General view and sectional view

P: From pilot pump P2: To control valve (blade LOWER port)

P1: To control valve (blade RAISE port) T: To hydraulic tank
1: Spool 2: Piston

10-136 PC45MR-5, PC55MR-5

10 STRUCTURE AND FUNCTION COMPONENT PARTS OF WORK EQUIPMENT SYSTEM

3: Lever 6: Body
4: Plate 7: Filter
5: Retainer
REMARK
For explanation of operation, see “OPERATION OF WORK EQUIPMENT AND SWING PPC VALVE”.

PC45MR-5, PC55MR-5 10-137

COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 10 STRUCTURE AND FUNCTION

BOOM SWING PPC VALVE

PPC
Abbreviation for Proportional Pressure Control

STRUCTURE OF BOOM SWING PPC VALVE

General view and sectional view

P: From pilot pump P2: Control valve (to boom swing left port)
P1: Control valve (to boom swing right port) T: To hydraulic tank
1: Spool 2: Piston

10-138 PC45MR-5, PC55MR-5

10 STRUCTURE AND FUNCTION COMPONENT PARTS OF WORK EQUIPMENT SYSTEM

3: Lever 6: Body
4: Plate 7: Filter
5: Retainer
REMARK
For explanation of operation, see “OPERATION OF WORK EQUIPMENT AND SWING PPC VALVE”.

PC45MR-5, PC55MR-5 10-139

COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 10 STRUCTURE AND FUNCTION

BIPARTITE SOLENOID VALVE

STRUCTURE OF BIPARTITE SOLENOID VALVE
General view and sectional view

A: To PPC valve P: From main pump

B: To 2nd travel speed selector solenoid valve T: To hydraulic tank

1: PPC lock solenoid valve

2: 2nd travel speed selector solenoid valve
3: Control relief valve
Solenoid valve
4: Coil (ON/OFF) type
5: Push pin
6: Valve spool
7: Return spring
8: Valve body
Control relief valve
9: Adjustment screw
10: Lock nut
11: Plug

10-140 PC45MR-5, PC55MR-5

10 STRUCTURE AND FUNCTION COMPONENT PARTS OF WORK EQUIPMENT SYSTEM

12: Return spring

13: Cover
14: Plunger

OPERATION OF SOLENOID VALVE

When the solenoid valve is “de-energized” (the circuit is blocked).
1. Coil (1) is de-energized when the signal current does not
flow to coil (1).
2. Spool (2) is pushed back to the left with the reaction force
of spring (3).
3. The circuit between port (P) and port (A) closes and pilot
pressure does not flow from port (A) to the actuator. At the
same time, port (T) opens and oil from the actuator is
drained to the hydraulic tank.

When the solenoid valve is “energized” (the circuit is connected).

1. Coil (1) is energized when the signal current flows to coil
(1).
2. Accordinglys, spool (2) is pushed to the right by push pin
(4).
3. The circuit between port (P) and port (A) opens and pilot
pressure flows from port (A) to the actuator. At the same
time, port (T) closes and oil from the actuator does not flow
to the hydraulic tank.

PC45MR-5, PC55MR-5 10-141

COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 10 STRUCTURE AND FUNCTION

OPERATION OF CONTROL RELIEF VALVE

1. As the oil pressure from the main pump increases, the oil
in port (P) pushes plunger (1).
2. The reaction force compresses spring (2) and moves
plunger (1) up, and connect ports (P) and (T) to relieve the
oil.
Set pressure: 3.14 MPa {32 kg/cm2}

10-142 PC45MR-5, PC55MR-5

10 STRUCTURE AND FUNCTION COMPONENT PARTS OF WORK EQUIPMENT SYSTEM

MULTI-CONTROL VALVE
(Machine with multi-control valve)

STRUCTURE OF MULTI-CONTROL VALVE

Control pattern changeover diagram

(Port names refer to symbols in drawing)

PC45MR-5, PC55MR-5 10-143

COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 10 STRUCTURE AND FUNCTION

PILOT CIRCUIT ACCUMULATOR

STRUCTURE OF PILOT CIRCUIT ACCUMULATOR
General view and sectional view
1: Gas plug
2: Shell
3: Poppet
4: Holder
5: Bladder
6: Oil port

SPECIFICATIONS OF PILOT CIRCUIT ACCUMULATOR

Gas used: Nitrogen gas
Volume of gas: 300 cc
Charged gas pressure: 1.18 MPa {12 kg/cm2} (at 80 °C)
Maximum using pressure: 6.87 MPa {70 kg/cm2}

FUNCTION OF PILOT CIRCUIT ACCUMULATOR

This accumulator (for pilot circuit) is installed between the main pump and solenoid valve. Even if the engine is
stopped while the work equipment is raised, pilot oil pressure can be supplied to the work equipment control
valve with the pressure of the compressed nitrogen gas in the accumulator. Accordingly, the work equipment
can be lowered by its own weight by operating the spool.

10-144 PC45MR-5, PC55MR-5

10 STRUCTURE AND FUNCTION LAYOUT DRAWING OF SWING SYSTEM

SWING SYSTEM
LAYOUT DRAWING OF SWING SYSTEM
Chassis part

1. Swing circle 4: Control valve

2: Swing motor 5: Main pump
3. Swing machinery

PC45MR-5, PC55MR-5 10-145

COMPONENT PARTS OF SWING SYSTEM 10 STRUCTURE AND FUNCTION

COMPONENT PARTS OF SWING SYSTEM

SWING MOTOR
STRUCTURE OF SWING MOTOR
General view

B: From control valve MB: From control valve (swing RIGHT port)
S: From control valve T: To hydraulic tank
MA: From control valve (swing LEFT port)

10-146 PC45MR-5, PC55MR-5

10 STRUCTURE AND FUNCTION COMPONENT PARTS OF SWING SYSTEM

Sectional view

1: Output shaft 9: Cylinder block

2: Housing 10: Brake piston
3: Shoe 11: Swash plate
4: Piston 12: Brake spring
5: Center spring 13: Check valve
6: Valve plate 14. Swing modulating relief valve
7: Disc 15: Brake ring
8: Plate

SPECIFICATIONS OF SWING MOTOR

Model: LMF16
Theoretical displacement: 16.1 cm3/rev
Rated speed: 2100 rpm

PC45MR-5, PC55MR-5 10-147

COMPONENT PARTS OF SWING SYSTEM 10 STRUCTURE AND FUNCTION

Rated flow rate: 34 ℓ/min

Suction valve cracking pressure: 0.04 MPa {0.45 kg/cm2}
Safety valve cracking pressure: 18.6 MPa {190 kg/cm2}

FUNCTION OF SWING MOTOR

The swing motor converts the fluid energy of hydraulic oil into rotational mechanical energy and swings the up-
per structure.

OPERATION OF SWING MOTOR

1. The pressurized oil being sent from the pump flows
through valve plate (7) into cylinder block (5). This oil flows
to only one side of line Y-Y connecting the top dead center
and bottom dead center during the stroke of piston (4).
2. Pressurized oil which flows in either side of cylinder block
(5) pushes pistons (4) (3 pieces or 4 pieces) and gener-
ates force F1 [F1 ( N { kg} ) = P ( MPa { kg/cm2} ) x
πD2/4 cm2].

3. This force acts on thrust plate (2) and is divided into com-
ponents (F2) and (F3) since the thrust plate is fixed at an-
gle (a) to output shaft (1).
4. Radial component (F3) of these components generates
torque (T = ∑(F3 x ri)] against (Y-Y) which is connecting
the top dead center and bottom dead center.
5. The combined force [T = ∑ (F3 x ri)] of these torques ro-
tates cylinder block (5) through pistons (4) as the rotating
torque.
6. The output shaft rotates and transmits the torque since this
cylinder block (5) is splined to the output shaft.

BRAKE VALVE OF SWING MOTOR

FUNCTION OF BRAKE VALVE OF SWING MOTOR
• The brake valve consists of the check valve and safety valve.
• When the swing is stopped, the control valve shuts off the motor outlet circuit, but the motor rotation is con-
tinued by inertial force. Accordingly, the motor outlet pressure becomes abnormally high and can damage
the motor.
• Abnormal pressure of the motor outlet side is released (high-pressure side) to port (S) to prevent damage
to the motor.

10-148 PC45MR-5, PC55MR-5

10 STRUCTURE AND FUNCTION COMPONENT PARTS OF SWING SYSTEM

OPERATION OF BRAKE VALVE OF SWING MOTOR

Operation when swing operation is started
1. The pressurized oil from the pump flows through control
valve (1) into port (MB) when the work equipment and
swing control lever is operated for swinging to the left.
2. The pressure in port (MB) increases, the starting torque is
generated to start rotating the motor.
3. The oil from the motor outlet returns to the tank via port
(MA) and control valve (1).

Operation when swing operation is stopped

1. When the work equipment and swing control lever is re-
turned to NEUTRAL position, the supply of the pressurized
oil from the pump to port (MB) stops.
2. The return circuit of the oil from the motor outlet to the tank
is closed by control valve (1). As a result, the increased
pressure in port (MA) generates the rotational resistance,
and the brake operates.
3. The pressure in port (MA) increases to the set pressure of
the safety valve, and braking torque higher than the motor
acts, and the motor stops.
4. While the safety valve is in operation, the oil relieved from
the safety valve and the oil from port (S) are supplied
through check valve (CB) to prevent cavitation at port
(MB).

PC45MR-5, PC55MR-5 10-149

COMPONENT PARTS OF SWING SYSTEM 10 STRUCTURE AND FUNCTION

SWING PARKING BRAKE OF SWING MOTOR

OPERATION OF SWING PARKING BRAKE OF SWING MOTOR
Operation when swing or arm control lever are in NEUTRAL
1. Brake piston (1) is pushed up by brake spring (2) since
PPC output pressure is 0 MPa {0 kg/cm2} .
2. Disc (3) and plate (4) are pressed, and the brake operates.

Operation when swing or arm control lever are operated

1. PPC output pressure flows through port (B) into brake
chamber (a).
2. The pressurized oil in chamber (a) presses down brake
spring (2).
3. Brake piston (1) moves downward and disc (3) and plate
(4) are separated, and the brake is released.

10-150 PC45MR-5, PC55MR-5

10 STRUCTURE AND FUNCTION COMPONENT PARTS OF SWING SYSTEM

Operation of hydraulic timer

• The hydraulic timer acts to delay the swing brake starting operation in order to ensure smooth deceleration
and to prevent damage to the parts of the motor when the swing brake is applied suddenly to stop the
swing motor.
1. PPC output pressure is applied to chamber (a) and the
swing brake is released when PPC lever is operated.
2. If PPC lever is set in neutral, no pressurized oil is supplied
to port (B), and the pressurized oil in chamber (a) is push-
ed out by brake spring (2).

3. The oil does not flow through on port (B) side but flows out
to passage (c) since the check valve is installed in the con-
trol valve.
4. The oil in chamber (a) flows out only slowly, and this de-
lays the actuation of the swing brake for a certain time pe-
riod since the oil passage is throttled by orifice (f) of brake
piston (1).

PC45MR-5, PC55MR-5 10-151

COMPONENT PARTS OF SWING SYSTEM 10 STRUCTURE AND FUNCTION

SWING MODULATING VALVE OF SWING MOTOR

FUNCTION OF SWING MODULATING VALVE OF SWING MOTOR
• The swing motor relief valve has characteristics of prevent-
ing sudden increase of the relief pressure to reduce
shocks generated when the machine stops and starts
swinging.

OPERATION OF SWING MODULATING VALVE OF SWING MOTOR

When circuit pressure is (P0)
1. The relief valve does not operate.
When the circuit pressure rises abruptly
1. When circuit pressure reaches (P1), pressure acts on the
area difference between (D1) and (D3) [(D1 > (D3)], and
oil presses spring (4), thus valve (3) starts opening.
2. At this time, pressure acts on the area difference between
(D1) and (D2) [(D2) > (D1)], thus seat (1) follows valve (3).
3. The relief passage to port (S) for the oil in chamber (a)
compressed by movement of seat (1) is narrowed by port
(2), thus seat (1) moves slower than valve (3).
4. Accordingly, the relief pressure increases gradually from
(P1) to (P2) until seat (1) reaches sleeve (5).

10-152 PC45MR-5, PC55MR-5

10 STRUCTURE AND FUNCTION COMPONENT PARTS OF SWING SYSTEM

SWING MACHINERY
STRUCTURE OF SWING MACHINERY
General view and sectional view

1: Swing motor 6: No. 2 sun gear (number of teeth: 21)

2: No. 1 sun gear (number of teeth: 21) 7: Swing pinion (number of teeth: 10)
3: No. 1 planetary gear (number of teeth: 33) 8: Taper roller bearing
4: Swing machinery case (number of teeth: 87) 9: No. 2 planetary carrier
5: No. 2 planetary gear (number of teeth: 33) 10: No. 1 planetary carrier

SPECIFICATIONS OF SWING MACHINERY

Reduction ratio: ((21 + 87) / 21 x (21 + 87) / 21) = 26.45
Swing reduction ratio: 26.45 x (92/9.0) = 238.04
Swing speed: 9.0 rpm
Lubricating oil: SAE10W
Amount of lubricating oil: 1.3 ℓ

PC45MR-5, PC55MR-5 10-153

COMPONENT PARTS OF SWING SYSTEM 10 STRUCTURE AND FUNCTION

FUNCTION OF SWING MACHINERY

The swing machinery reduces the swing motor speed, increases the swing force, and reduces the swing speed
to proper speed.

10-154 PC45MR-5, PC55MR-5

10 STRUCTURE AND FUNCTION COMPONENT PARTS OF SWING SYSTEM

SWING CIRCLE
STRUCTURE OF SWING CIRCLE
General view and sectional view

a: Position of inner race soft zone b: Position of outer race soft zone
1: Greasing port of swing circle bearing 4: Inner race
2: Greasing port of swing circle pinion 5: Ball
3: Outer race 6: Seal

SPECIFICATIONS OF SWING CIRCLE

Reduction ratio: 90/10 = 9.00
Grease: G2-LI

FUNCTION OF SWING CIRCLE

The swing circle connects the upper structure and carrier unit.

PC45MR-5, PC55MR-5 10-155

LAYOUT DRAWING OF TRAVEL SYSTEM 10 STRUCTURE AND FUNCTION

TRAVEL SYSTEM
LAYOUT DRAWING OF TRAVEL SYSTEM
Chassis part

1: Travel alarm 6: Control valve

2: Engine controller 7: Main pump
3: 2nd travel speed selector solenoid valve 8: Travel PPC pressure sensor
4: Center swivel joint 9: Travel motor (L.H.)
5: Travel motor (R.H.)

10-156 PC45MR-5, PC55MR-5

10 STRUCTURE AND FUNCTION LAYOUT DRAWING OF TRAVEL SYSTEM

Around cab and floor

1: Travel lever 3: Travel pedal

2: Machine controller 4: Travel PPC valve

PC45MR-5, PC55MR-5 10-157

TRAVEL CONTROL SYSTEM DIAGRAM 10 STRUCTURE AND FUNCTION

TRAVEL CONTROL SYSTEM DIAGRAM

Input and output signals

a: Oil pressure sensor signal d: Travel alarm operation signal
b: 2nd travel speed selector solenoid valve drive sig- e: Travel speed selector switch signal
nal
c: CAN signal
1: Machine controller 6: Main pump
2: Engine controller 7: Control valve
3: Machine monitor 8: Travel motor
4: Oil pressure sensor 9: 2nd travel speed selector solenoid valve
5: Travel alarm 10: Travel speed selector switch

FUNCTION OF TRAVEL CONTROL SYSTEM

Travel speed selector function
Operating the travel speed selector switch of the blade lever changes the motor capacity, and travel speed.
REMARK
The travel speed is set to low speed (Lo) automatically if the load increases on a soft ground or on a slope even
while the machine is traveling at high speed (Hi).
The travel speed displayed on the machine monitor remains (Hi) at this time.
Travel speed selector switch Lo (Low speed) Hi (High speed)
2nd travel speed selector solenoid valve OFF ON
Motor capacity 24.7 cc/rev 14.3 cc/rev
Travel speed 2.6 km/h 4.6 km/h

10-158 PC45MR-5, PC55MR-5

10 STRUCTURE AND FUNCTION TRAVEL CONTROL SYSTEM DIAGRAM

Travel motor swash plate angle Maximum Minimum

A: 21.6 MPa {221 kg/cm2}
B: 23.1 MPa {236 kg/cm2}

PC45MR-5, PC55MR-5 10-159

COMPONENT PARTS OF TRAVEL SYSTEM 10 STRUCTURE AND FUNCTION

COMPONENT PARTS OF TRAVEL SYSTEM

TRAVEL MOTOR
STRUCTURE OF TRAVEL MOTOR
General view

L.H. travel motor

A: From control valve (left travel FORWARD port)
B: From control valve (left travel REVERSE port)
DR1: To hydraulic tank
DR2: Plug
PP: From 2nd travel speed solenoid valve
R.H. travel motor
A: From control valve (right travel REVERSE port)
B: From control valve (right travel FORWARD port)
DR1: Plug
DR2: To hydraulic tank
PP: From 2nd travel speed solenoid valve

10-160 PC45MR-5, PC55MR-5

10 STRUCTURE AND FUNCTION COMPONENT PARTS OF TRAVEL SYSTEM

Sectional view

1: Oil filler plug 14: Disc

2: Cover 15: Shaft
3: No. 2 planetary gear 16: Rocker cam
4: No. 2 sun gear 17: Control piston
5: Ring gear 18: No. 1 planetary gear
6: Ball 19: No. 1 sun gear
7: Housing 20: No. 2 planetary carrier
8: Piston 21: Drain plug
9: Cylinder 22: Oil level plug
10: Valve plate 23: Check valve
11: Brake valve 24: Counterbalance valve
12: Brake piston 25: Check valve
13: Plate 26: Automatic gear shift valve

PC45MR-5, PC55MR-5 10-161

COMPONENT PARTS OF TRAVEL SYSTEM 10 STRUCTURE AND FUNCTION

Structure
• Swash plate (1) has 2 planes of x and y, and is supported
on ball (2).
• The travel speed is changed by setting the angle of swash
plate (1) to the maximum or minimum with the pressurized
oil from control chamber (a) which acts on control piston
(3).

SPECIFICATIONS OF TRAVEL MOTOR

Model: PHV-4B-60C-PT-9480Z3
Theoretical displacement (Lo): 24.7 cm3/rev
Theoretical displacement (Hi): 14.3 cm3/rev
Rated speed (Lo): 2227 rpm
Rated speed (Hi): 3846 rpm
Brake releasing pressure: 1.13 MPa {11.5 kg/cm2}
Travel speed selector pressure: 0.86 MPa {8.8 kg/cm2}
Automatic gear shift selecting pressure (Lo→Hi): 21.6 MPa {221 kg/cm2}
Automatic gear shift selecting pressure (Hi→Lo): 23.1 MPa {236 kg/cm2}
Reduction ratio: 63.80

FUNCTION OF TRAVEL MOTOR

The travel motor converts the fluid energy of hydraulic oil into rotational mechanical energy, and travels the ma-
chine.

10-162 PC45MR-5, PC55MR-5

10 STRUCTURE AND FUNCTION COMPONENT PARTS OF TRAVEL SYSTEM

MOTOR PORTION OF TRAVEL MOTOR

OPERATION OF MOTOR PART OF TRAVEL MOTOR
Operation at low speed (motor swash plate angle is at maximum)

1. The hydraulic oil from the pilot pump does not flow to port PP since 2nd travel speed selector solenoid
valve (1) is de-energized.
2. The circuit to control chamber (a) is shut off since automatic gear shift valve (2) pressed down by spring (3).
3. Swash plate (6) is pressed to the right by the reaction force of center spring (7) since control chamber (a) is
connected to the drain port.
4. Swash plate (6) leans around ball (8) toward the maximum swash plate angle side, the motor capacity be-
comes maximum, and the travel speed decreases.

PC45MR-5, PC55MR-5 10-163

COMPONENT PARTS OF TRAVEL SYSTEM 10 STRUCTURE AND FUNCTION

Operation at high speed (motor swash plate angle is at minimum)

1. The pilot pressure from the pilot pump flows to port PP when 2nd travel speed selector solenoid valve (1) is
energized.
2. Automatic gear shift valve (2) compresses spring (3) and moves up, and the circuit to control chamber (a) is
connected.
3. The pressurized oil from the control valve flows from automatic gear shift valve (2) through check valve (4)
to control chamber (a), and pushes control piston (5) to the left.
4. Swash plate (6) leans around ball (8) toward the minimum swash plate angle side against center spring (7),
the motor capacity becomes minimum, and the travel speed increases.
REMARK
The automatic gear shift function works only while the travel speed selector switch is set in the high speed posi-
tion. See “OPERATION OF AUTOMATIC GEAR SHIFT VALVE OF TRAVEL MOTOR”.

10-164 PC45MR-5, PC55MR-5

10 STRUCTURE AND FUNCTION COMPONENT PARTS OF TRAVEL SYSTEM

PARKING BRAKE OF TRAVEL MOTOR

OPERATION OF PARKING BRAKE OF TRAVEL MOTOR
Operation when travel lever is operated
1. When the travel lever is operated, the pressurized oil from
the pump flows in chamber (a) of brake piston (1) and
pushes brake piston (1) to the right.
2. The pressing force of spring (4) against plate (2) and disc
(3) is lost.
3. Plate (2) and disc (3) are separated and the brake is re-
leased.

Operation when travel lever is in NEUTRAL

1. When the travel lever is set in NEUTRAL, the pressurized
oil in chamber (a) of brake piston (1) is blocked.
2. Piston (1) is pushed to the left by spring (4).
3. Plate (2) and disc (3) are pressed, and the brake is ap-
plied.

COUNTERBALANCE VALVE AND CHECK VALVE OF TRAVEL MOTOR

OPERATION OF COUNTERBALANCE VALVE AND CHECK VALVE OF TRAVEL
MOTOR
Operation when the pressurized oil is supplied
1. When the travel lever is operated, the pressurized oil from
the control valve is supplied to port (A).
2. It pushes open check valve (1), and flows from motor inlet
port (MA) to motor outlet port (MB).
3. The pressurized oil flows through orifice (c) into chamber
D, and pushes spool (3) to the right against spring (2).
4. Ports (MB) and (B) are connected, the motor outlet side
opens, and the motor starts rotation.

PC45MR-5, PC55MR-5 10-165

COMPONENT PARTS OF TRAVEL SYSTEM 10 STRUCTURE AND FUNCTION

Operation when the pressurized oil is blocked

1. The pressurized oil from the control valve is blocked when
the travel lever is returned to NEUTRAL.
2. The reaction force of spring (2) pushes back spool (3) to
the left.
3. The pressurized oil in chamber (D) flows into port (A)
through orifice (c). At this time, the back pressure is gener-
ated by the throttle effect of orifice (c), and it controls the
speed of spool (3) returning to the left.
4. Even after the pressurized oil in port (A) is blocked, the
motor continues the rotation by inertial force.
5. The motor stops smoothly by the returning oil being con-
trolled with the changing speed and shape of the notch of spool (3).

AUTOMATIC GEAR SHIFT VALVE OF TRAVEL MOTOR

OPERATION OF AUTOMATIC GEAR SHIFT VALVE OF TRAVEL MOTOR
Operation in automatic change of travel speed from high speed (Hi) to low
speed (Lo)

1. Motor drive pressure (Pc) is led into chambers (a) and (b) of automatic gear shift valve (1) while the ma-
chine is traveling at high speed with the travel speed selector switch in the high speed position.
2. The total of force (F1) generated by the difference of the pressure receiving area between chambers (a)
and (b) (a > b) and reaction force (F2) of spring (2) becomes larger than force (F3) generated by pilot pres-
sure (PP) when motor drive pressure (Pc) increases.
3. As a result, automatic gear shift valve (1) moves to the left and shuts off motor drive pressure (A) which is
flowing into control chamber (c).
4. Port DR opens and the oil in control chamber (c) is drained and control piston (3) moves to the left.

10-166 PC45MR-5, PC55MR-5

10 STRUCTURE AND FUNCTION COMPONENT PARTS OF TRAVEL SYSTEM

5. The swash plate of motor (4) leans toward the maximum swash plate angle side and the travel speed de-
creases.
Operation in automatic gear shift from low speed (Lo) to high speed (Hi)

1. While the machine is traveling at low speed with the travel speed selector switch in the high speed position,
motor drive pressure (Pc) is led into chamber (a) of automatic gear shift valve (1).
(Chamber "b" is connected to port DR)
2. The total of force (F1) generated in chamber (a) by motor drive pressure (Pc) and reaction force (F2) of
spring (2) becomes smaller than force (F3) generated by pilot pressure (PP) when motor drive pressure
(Pc) decreases.
3. Automatic gear shift valve (1) moves to the right and motor drive pressure (A) flows into control chamber
(c).
4. Port DR closes, oil flows into control chamber (c), and control piston (3) moves to the right.
5. The swash plate of motor (4) leans toward the minimum swash plate angle side, and the machine travels
with high speed.

PC45MR-5, PC55MR-5 10-167

COMPONENT PARTS OF TRAVEL SYSTEM 10 STRUCTURE AND FUNCTION

TRAVEL PPC VALVE

PPC
Abbreviation for Proportional Pressure Control

STRUCTURE OF TRAVEL PPC VALVE

General view

P: From pilot pump P3: To control valve (L.H. forward port)

P1: To control valve (R.H. forward port) P4: To control valve (L.H. reverse port)
P2: To control valve (R.H. reverse port) T: To hydraulic tank

10-168 PC45MR-5, PC55MR-5

10 STRUCTURE AND FUNCTION COMPONENT PARTS OF TRAVEL SYSTEM

Sectional view

1: Plate 4: Seal
2: Case 5: Spool
3: Piston 6: Damper
REMARK
For explanation of operation, see “OPERATION OF WORK EQUIPMENT AND SWING PPC VALVE”.

PC45MR-5, PC55MR-5 10-169

COMPONENT PARTS OF TRAVEL SYSTEM 10 STRUCTURE AND FUNCTION

CENTER SWIVEL JOINT

STRUCTURE OF CENTER SWIVEL JOINT
General view and sectional view

A1: From control valve (left travel REVERSE port) E1: From 2nd travel speed selector solenoid valve
A2: To L.H. travel motor port B E2: To 2nd travel speed selector valve
B1: From control valve (left travel FORWARD port) F1: From control valve (blade RAISE port)
B2: To L.H. travel motor port A F2: To blade cylinder head
C1: From control valve (right travel REVERSE port) G1: From control valve (blade LOWER port)
C2: To R.H. travel motor port A G2: To blade cylinder bottom
D1: From control valve (right travel FORWARD port) T1: To hydraulic tank
D2: To L.H. travel motor port B T2: From travel motor drain port
1: Cover 3: Slipper seal
2: Rotor 4: Shaft

FUNCTION OF CENTER SWIVEL JOINT

The center swivel joint sends oil from the main pump installed to the top of the machine to the travel motor and
blade installed to the bottom of the machine while turning. The center swivel joint is installed in order for the
hoses and tubes not to be twisted, since the upper portion of the machine rotates against the lower portion of
the machine.

10-170 PC45MR-5, PC55MR-5

10 STRUCTURE AND FUNCTION LAYOUT DRAWING OF UNDERCARRIAGE

UNDERCARRIAGE AND FRAME

LAYOUT DRAWING OF UNDERCARRIAGE

1: Idler 5: Travel motor

2: Track frame 6: Track roller
3: Carrier roller 7: Idler guard (*1)
4: Sprocket 8: Track shoe
*1: Machines with steel shoe

SPECIFICATIONS OF UNDERCARRIAGE
Number of carrier rollers (one side)
1 piece
Number of track rollers (one side)
4 pieces

PC45MR-5, PC55MR-5 10-171

IDLER CUSHION 10 STRUCTURE AND FUNCTION

IDLER CUSHION
STRUCTURE OF IDLER CUSHION
Sectional view

1: Rod 4: Rear support

2: Cylinder 5: Nut
3: Recoil spring 6: Lubricator

SPECIFICATIONS OF IDLER CUSHION

Grease: G2-LI
Quantity of grease: 120 cc

10-172 PC45MR-5, PC55MR-5

10 STRUCTURE AND FUNCTION STRUCTURE OF WORK EQUIPMENT

WORK EQUIPMENT
STRUCTURE OF WORK EQUIPMENT
General view

1: Arm cylinder 7: Blade

2: Boom 8: Bucket
3: Boom cylinder 9: Bucket link
4: Boom swing cylinder 10: Bucket cylinder
5: Boom swing bracket 11: Arm
6: Blade cylinder

PC45MR-5, PC55MR-5 10-173

FUNCTION OF WORK EQUIPMENT 10 STRUCTURE AND FUNCTION

FUNCTION OF WORK EQUIPMENT

• The boom is operated by the boom cylinder. The boom moves the whole work equipment upward and
downward.
• The arm is operated by the arm cylinder. The boom pulls in or pushes out the bucket.
• The bucket is operated by the bucket cylinder and the bucket link.
• The bucket link increases the moving range of the bucket.
• The blade is operated by the blade cylinder.
• The boom swing bracket can swing the boom swing direction to the right or left by the boom swing cylinder.

10-174 PC45MR-5, PC55MR-5

10 STRUCTURE AND FUNCTION WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM

WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM

FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM
There are 2 types of the work equipment clearance adjustment shims. The steel shim and plastic shim. The fol-
lowing is the explanation of the function of each type of clearance adjustment shim.
Steel shim

The purpose of the steel shim is to reduce the clearance in the right and left direction. There may be some cas-
es that shim is unnecessary to be inserted on one side if it is inserted in either on right or left side depending on
the width of the clearance.
Plastic shim

The purpose of the plastic shim is to reduce the clearance in the right and left direction of the work equipment,
and to prevent a creak and scuffing caused by rubbing of the end faces of steel parts of a joint.

PC45MR-5, PC55MR-5 10-175

ROPS CAB 10 STRUCTURE AND FUNCTION

CAB AND ITS ATTACHMENTS

ROPS CAB
ROPS
Abbreviation for Roll-Over Protective Structure

STRUCTURE OF ROPS CAB

REMARK
The figure shows the cab specifications.
General view

1: Windshield wiper 5: Radio antenna

2: Front window 6: Door
3: Mirror 7: KOMTRAX communication antenna
4: Head lamp 8: KOMTRAX GPS antenna

FUNCTION OF ROPS CAB

ROPS cab protects the operator wearing seat belt from being crushed when the machine rolls over.

10-176 PC45MR-5, PC55MR-5

10 STRUCTURE AND FUNCTION TILT TYPE FLOOR

TILT TYPE FLOOR

STRUCTURE OF TILT TYPE FLOOR
General view

1: Gas spring 5: Tilt lock bracket

2: Wire 6: Cancel lever
3: Hinge pin 7: Floor assembly
4: Lock pin

FUNCTION OF TILT TYPE FLOOR

The tilt type floor can be tilted open to facilitate the adjusting of the fan belt, replacement of the hydraulic hoses,
etc. for better performance of inspection and maintenance.
Tilt open angle: Approximately 35 °

PC45MR-5, PC55MR-5 10-177

20 STANDARD VALUE TABLE

S/T
Steering
STRG
SIG Signal
SOL Solenoid
STD Standard
OPT
Option
OP
PRESS Pressure
SPEC Specification
SW Switch
TEMP Temperature
T/C Torque Converter
T/M Transmission

20-8 PC45MR-5, PC55MR-5

20 STANDARD VALUE TABLE STANDARD VALUE TABLE FOR ENGINE: PC45MR-5

STANDARD VALUE TABLE FOR ENGINE

STANDARD VALUE TABLE FOR ENGINE: PC45MR-5
Performance
Machine model PC45MR-5
Engine 4D88E-7
Standard value
Item Measurement condition Unit Repair limit
for new machine
2550±50 2550±50
• Engine coolant temperature: 60 to 100 °C (When the maxi- (When the maxi-
mum value for mum value for
• Hydraulic oil temperature: 45 to 55 °C turning and trav- turning and trav-
Engine speed • Fuel control dial: MAX (High idle) position eling) eling)
rpm
at high idle • Working mode: P (Power Mode) 2430±50 2430±50
• Travel speed: Hi (When the posi- (When the posi-
• Auto-deceleration switch: OFF tion of the oper- tion of the oper-
ating lever is in ating lever is in
neutral) neutral)
• Engine coolant temperature: 60 to 100 °C
• Hydraulic oil temperature: 45 to 55 °C
Engine speed
• Fuel control dial: MIN (Low idle) position rpm 1225±50 1225±50
at low idle
• Working mode: P (Power Mode)
• Auto-deceleration switch: OFF

Air intake and exhaust system

Machine model PC45MR-5
Engine 4D88E-7
Standard value
Item Measurement condition Unit Repair limit
for new machine
• Engine coolant temperature: 60 to 100 °C
• After keeping it at normal condition for 5
Exhaust gas seconds Bosch in-
Max. 0.5 Max. 1.5
color dex
• Fuel control dial: MAX (High idle) position
• Auto-deceleration switch: OFF

Valve clear- Engine coolant temperature: Intake valve 0.20±0.05 0.20±0.05

mm
ance Normal temperature Exhaust valve 0.20±0.05 0.20±0.05

Main body
Machine model PC45MR-5
Engine 4D88E-7
Standard value
Item Measurement condition Unit Repair limit
for new machine
• Engine coolant temperature: 40 to 60 °C
Compression MPa 3.14 to 3.43 2.45 to 2.65
pressure • At cranking (engine speed): 250 rpm (refer-
{ kg/cm2} {32 to 35} {25 to 28}
ence)

PC45MR-5, PC55MR-5 20-9

STANDARD VALUE TABLE FOR ENGINE: PC45MR-5 20 STANDARD VALUE TABLE

Lubrication system
Machine model PC45MR-5
Engine 4D88E-7
Standard value
Item Measurement condition Unit Repair limit
for new machine
• Engine coolant tempera- Fuel control di- 0.32 to 0.47 Min. 0.05
ture: 60 to 100 °C al: MAX (High
idle) position {3.3 to 4.8} {Min. 0.51}
• Working mode: P (Power
Mode)
• Each control lever and
Engine oil MPa
control pedal in NEUTRAL
pressure position Fuel control di- { kg/cm2}
Min. 0.06 Min. 0.05
al: MIN (Low
• Engine oil {Min. 0.6} {Min. 0.51}
idle) position
EO10W30-LA
EO15W40-LA
EO30-DH
Engine oil tem-
Whole speed range (inside oil pan) °C Max. 120 Max. 120
perature

Cooling system
Machine model PC45MR-5
Engine 4D88E-7
Item Measurement condition Unit Standard value Repair limit
for new machine
Between alter-
nator and
8 to 12 10 to 14
crankshaft pul-
Deflection when pressed with ley
finger approximately 98 N {ap-
Tension of al- Between alter-
proximately 10 kg} (measure at mm
ternator belt nator and fan 5 to 8 7 to 10
any intermediate points descri-
pulley
bed in the right column)
Between crank-
shaft pulley 7 to 11 9 to 13
and fan pulley
• Between compressor pulley and idler pul-
Air conditioner ley
compressor mm 5 to 6 5 to 6
belt tension • Deflection when pressed with finger at
58.8 N {6.0 kg}

20-10 PC45MR-5, PC55MR-5

20 STANDARD VALUE TABLE STANDARD VALUE TABLE FOR ENGINE: PC55MR-5

STANDARD VALUE TABLE FOR ENGINE: PC55MR-5

Performance
Machine model PC55MR-5
Engine 4D88E-7
Standard value
Item Measurement condition Unit Repair limit
for new machine
2550±50 2550±50
• Engine coolant temperature: 60 to 100 °C (When the maxi- (When the maxi-
mum value for mum value for
• Hydraulic oil temperature: 45 to 55 °C turning and trav- turning and trav-
Engine speed • Fuel control dial: MAX (High idle) position eling) eling)
rpm
at high idle • Working mode: P (Power Mode) 2430±50 2430±50
• Travel speed: Hi (When the posi- (When the posi-
• Auto-deceleration switch: OFF tion of the oper- tion of the oper-
ating lever is in ating lever is in
neutral) neutral)
• Engine coolant temperature: 60 to 100 °C
• Hydraulic oil temperature: 45 to 55 °C
Engine speed
• Fuel control dial: MIN (Low idle) position rpm 1225±50 1225±50
at low idle
• Working mode: P (Power Mode)
• Auto-deceleration switch: OFF

Air intake and exhaust system

Machine model PC55MR-5
Engine 4D88E-7
Standard value
Item Measurement condition Unit Repair limit
for new machine
• Engine coolant temperature: 60 to 100 °C
• After keeping it at normal condition for 5
Exhaust gas seconds Bosch in-
Max. 0.5 Max. 1.5
color dex
• Fuel control dial: MAX (High idle) position
• Auto-deceleration switch: OFF

Valve clear- Engine coolant temperature: Intake valve 0.20±0.05 0.20±0.05

mm
ance Normal temperature Exhaust valve 0.20±0.05 0.20±0.05

Main body
Machine model PC55MR-5
Engine 4D88E-7
Standard value
Item Measurement condition Unit Repair limit
for new machine
• Engine coolant temperature: 40 to 60 °C
Compression MPa 3.14 to 3.43 2.45 to 2.65
pressure • At cranking (engine speed): 250 rpm (refer-
{ kg/cm2} {32 to 35} {25 to 28}
ence)

PC45MR-5, PC55MR-5 20-11

STANDARD VALUE TABLE FOR ENGINE: PC55MR-5 20 STANDARD VALUE TABLE

Lubrication system
Machine model PC55MR-5
Engine 4D88E-7
Standard value
Item Measurement condition Unit Repair limit
for new machine
• Engine coolant tempera- Fuel control di- 0.32 to 0.47 Min. 0.05
ture: 60 to 100 °C al: MAX (High
idle) position {3.3 to 4.8} {Min. 0.51}
• Working mode: P (Power
Mode)
• Each control lever and
Engine oil MPa
control pedal in NEUTRAL
pressure position Fuel control di- { kg/cm2}
Min. 0.06 Min. 0.05
al: MIN (Low
• Engine oil {Min. 0.6} {Min. 0.51}
idle) position
EO10W30-LA
EO15W40-LA
EO30-DH
Engine oil tem-
Whole speed range (inside oil pan) °C Max. 120 Max. 120
perature

Cooling system
Machine model PC55MR-5
Engine 4D88E-7
Item Measurement condition Unit Standard value Repair limit
for new machine
Between alter-
nator and
8 to 12 10 to 14
crankshaft pul-
Deflection when pressed with ley
finger approximately 98 N {ap-
Tension of al- Between alter-
proximately 10 kg} (measure at mm
ternator belt nator and fan 5 to 8 7 to 10
any intermediate points descri-
pulley
bed in the right column)
Between crank-
shaft pulley 7 to 11 9 to 13
and fan pulley
• Between compressor pulley and idler pul-
Air conditioner ley
compressor mm 5 to 6 5 to 6
belt tension • Deflection when pressed with finger at
58.8 N {6.0 kg}

20-12 PC45MR-5, PC55MR-5

20 STANDARD VALUE TABLE STANDARD VALUE TABLE FOR MACHINE: PC45MR-5

STANDARD VALUE TABLE FOR MACHINE

STANDARD VALUE TABLE FOR MACHINE: PC45MR-5
Engine speed
Machine model PC45MR-5
Engine 4D88E-7
Standard value
Item Measurement condition Unit Repair limit
for new machine
• Engine coolant temperature: 60 to 100 °C

Engine speed • Hydraulic oil temperature: 45 to 55 °C

at 1-pump re- • Fuel control dial: MAX (High idle) position Min. 2220 Min. 2220
lief • Working mode: P (Power Mode)
• Arm CURL relief
• Engine coolant temperature: 60 to 100 °C

Engine speed • Hydraulic oil temperature: 45 to 55 °C

at 2-pump re- • Fuel control dial: MAX (High idle) position Min. 2150 Min. 2150
lief • Working mode: P (Power Mode) rpm

• Arm CURL relief + Blade relief

• Engine coolant temperature: 60 to 100 °C
• Hydraulic oil temperature: 45 to 55 °C
Engine speed
• Working mode: P (Power Mode)
when auto-de-
• Auto-deceleration switch: ON 1225±50 1225±50
celeration is
operated • Approximately 5 seconds after each con-
trol lever and control pedal are set in NEU-
TRAL

Control valve spool stroke

Machine model PC45MR-5
Engine 4D88E-7
Standard value
Item Measurement condition Unit Repair limit
for new machine
Boom
Arm
Bucket
Swing • Spool operation of control valve unit ℓ = 30 ℓ = 30
Breaker • Measurement posture: See “MACHINE mm a=6 a=6
POSTURE AND PROCEDURE FOR
Boom swing b=6 b=6
MEASURING PERFORMANCE”, “Fig. 1”.
Blade
L.H. travel
R.H. travel

PC45MR-5, PC55MR-5 20-13

STANDARD VALUE TABLE FOR MACHINE: PC45MR-5 20 STANDARD VALUE TABLE

Stroke of control lever and pedal

Machine model PC45MR-5
Engine 4D88E-7
Standard value
Item Measurement condition Unit Repair limit
for new machine
N → Boom
Boom control
RAISE, Boom 85±10 85±10
lever
LOWER
Arm control N → Arm IN,
85±10 85±10
lever Arm OUT
N → Bucket
Bucket control
CURL, Bucket 85±10 85±10
lever
DUMP
N → Swing
Swing control
LEFT, Swing 85±10 85±10
lever • Engine: Stopped
RIGHT
• Center of lever knob
N → Swing
Boom swing • End of pedal LEFT, Swing mm 25±5 25±5
control pedal
• Read maximum value RIGHT
through travel end (exclud-
Blade control N → RAISE,
ing play at NEUTRAL). 50±5 50±5
lever LOWER
N → Travel
FORWARD,
Travel control
Travel RE- 100±10 100±10
lever
VERSE
(RIGHT/LEFT)
Work equip-
Play of control ment, Swing, Max. 5 Max. 5
lever Blade
Travel Max. 5 Max. 5

20-14 PC45MR-5, PC55MR-5

20 STANDARD VALUE TABLE STANDARD VALUE TABLE FOR MACHINE: PC45MR-5

Operating effort of control lever and pedal

Machine model PC45MR-5
Engine 4D88E-7
Standard value
Item Measurement condition Unit Repair limit
for new machine

Boom control 15.68±4.9 15.68±9.8

lever {1.6±0.5} {1.6±1}

Arm control 15.68±4.9 15.68±9.8

lever {1.6±0.5} {1.6±1}

Bucket control 15.68±4.9 15.68±9.8

lever • Hydraulic oil temperature: 45 to 55 °C {1.6±0.5} {1.6±1}
• Fuel control dial: MAX (High idle) position
Swing control N 15.68±4.9 15.68±9.8
lever • Hitch push-pull scale to center of lever grip
{ kg} {1.6±0.5} {1.6±1}
or end of pedal to measure
Boom swing • Read maximum value through travel end 78.4±19.6 78.4±29.4
control pedal {8.0±2.0} {8.0±3.0}

Blade control 29.4±9.8 29.4±19.6

lever {3.0±1.0} {3.0±2}

Travel control 22.5±4.9 22.5±9.8

lever {2.3±0.5} {2.3±1}

Work equipment, swing, boom swing, and travel oil pressures

Machine model PC45MR-5
Engine 4D88E-7
Standard value
Item Measurement condition Unit Repair limit
for new machine
• Hydraulic oil temperature: 45 to 55 °C
• Fuel control dial: MAX (High idle) position
Unload pres- • Working mode: P (Power Mode) MPa 2.94±0.49 2.94±0.49
sure • Auto-deceleration switch: OFF { kg/cm2} {30±5} {30±5}
• Each control lever and control pedal: NEU-
TRAL position
Boom relief 26.5±0.98 26.5±0.98
pressure {270±10} {270±10}

Arm relief 26.5±0.98 26.5±0.98

pressure
• Hydraulic oil temperature: 45 to 55 °C
{270±10} {270±10}
• Fuel control dial: MAX (High idle) position
Bucket relief 26.5±0.98 26.5±0.98
• Working mode: P (Power Mode)
pressure MPa {270±10} {270±10}

Boom swing { kg/cm2} 26.5±0.98 26.5±0.98

relief pressure {270±10} {270±10}
• Hydraulic oil temperature: 45 to 55 °C
Swing relief • Fuel control dial: MAX (High idle) position 19.6±0.98 19.6±0.98
pressure • Working mode: P (Power Mode) {200±10} {200±10}
• Auto-deceleration switch: OFF

PC45MR-5, PC55MR-5 20-15

STANDARD VALUE TABLE FOR MACHINE: PC45MR-5 20 STANDARD VALUE TABLE

Machine model PC45MR-5

Engine 4D88E-7
Standard value
Item Measurement condition Unit Repair limit
for new machine

Engine 4D88E-7
Standard value
Item Measurement condition Unit Repair limit
for new machine
• Hydraulic oil temperature: Lo Max. 300 Max. 330
45 to 55 °C
• Fuel control dial: MAX
(High idle) position
• Working mode: P (Power
Mode)
• Travel deviation (X) in trav-
Travel devia- el of 20 m after running up mm
tion 10 m on a firm and level Hi Max. 300 Max. 330
ground
• Measurement posture:
See “MACHINE POS-
TURE AND PROCEDURE
FOR MEASURING PER-
FORMANCE”, “Fig. 4” and
“Fig. 5”.
• Hydraulic oil temperature: 45 to 55 °C
• Engine: Stopped
• Place machine on slope of 30 ° with
sprocket on uphill side.
Machine drift
• Travel distance by machine drift on a slope mm 0 0
on slope
for 5 minutes
• Measurement posture: See “MACHINE
POSTURE AND PROCEDURE FOR
MEASURING PERFORMANCE”, “Fig. 6”.

PC45MR-5, PC55MR-5 20-19

STANDARD VALUE TABLE FOR MACHINE: PC45MR-5 20 STANDARD VALUE TABLE

Hydraulic drift of work equipment

Machine model PC45MR-5
Engine 4D88E-7
Standard value
Item Measurement condition Unit Repair limit
for new machine
Whole work • Level and flat ground
equipment
(Hydraulic drift • Hydraulic oil temperature: 45 to 55 °C Max. 300 Max. 450
measured at • Engine: Stopped
tooth tip)
• Each control lever and control pedal: NEU-
Boom cylinder TRAL position
(Retraction • Bucket: Rated load (Rated load: 2254 N Max. 6 Max. 30
amount of cyl- {230 kg} )
inder)
• Start the measurement of hydraulic drift of
Arm cylinder work equipment immediately after setting
(Extension the machine in measuring posture Max. 30 Max. 30
amount of cyl-
inder) • Measure hydraulic drift every 5 minutes
and judge at 15 minutes.
Bucket cylin-
der (Retraction • Measurement posture: See “MACHINE
POSTURE AND PROCEDURE FOR Max. 16 Max. 30
amount of cyl-
inder) MEASURING PERFORMANCE”, “Fig. 7”. mm
• Hydraulic oil temperature: 45 to 55 °C
• Engine: Stopped
Boom swing • Bucket: Rated load (Rated load: 2254 N
cylinder (Re-
{230 kg})
traction
amount and • Set the upper structure sideways on 15 Max. 20 Max. 30
extension deg. slope. Measure retraction and exten-
amount of cyl- sion amounts for 15 minutes.
inder) • Measurement posture: See “MACHINE
POSTURE AND PROCEDURE FOR
MEASURING PERFORMANCE”, “Fig. 7”.
• Hydraulic oil temperature: 45 to 55 °C
Blade (Hy-
• Engine: Stopped
draulic drift of Max. 30 Max. 45
blade edge) • Measure hydraulic drift of blade edge from
maximum raising position for 15 minutes.

20-20 PC45MR-5, PC55MR-5

20 STANDARD VALUE TABLE STANDARD VALUE TABLE FOR MACHINE: PC45MR-5

Work equipment speed

Machine model PC45MR-5
Engine 4D88E-7
Standard value
Item Measurement condition Unit Repair limit
for new machine
• Hydraulic oil temperature: RAISE 2.8±0.3 Max. 3.4
45 to 55 °C
• Fuel control dial: MAX
(High idle) position
• Working mode: P (Power
Mode)
Boom speed • Time required to move Sec.
bucket teeth from ground LOWER 2.8±0.3 Max. 3.4
to RAISE stroke end
• Measurement posture:
See “MACHINE POS-
TURE AND PROCEDURE
FOR MEASURING PER-
FORMANCE”, “Fig. 8”.
• Hydraulic oil temperature: Arm IN 3.0±0.3 Max. 3.6
45 to 55 °C
• Fuel control dial: MAX
(High idle) position
• Working mode: P (Power
Mode)
Arm speed • Time required for opera- Sec.
tion between dump stroke DUMP 2.5±0.3 Max. 3.0
end and arm IN stroke end
• Measurement posture:
See “MACHINE POS-
TURE AND PROCEDURE
FOR MEASURING PER-
FORMANCE”, “Fig. 9”.
• Hydraulic oil temperature: Bucket CURL 2.9±0.3 Max. 3.5
45 to 55 °C
• Fuel control dial: MAX
(High idle) position
• Working mode: P (Power
Mode)
Bucket speed • Time required for opera- Sec.
tion between dump stroke DUMP 2.0±0.3 Max. 2.4
end and arm IN stroke end
• Measurement posture:
See “MACHINE POS-
TURE AND PROCEDURE
FOR MEASURING PER-
FORMANCE”, “Fig. 10”.

PC45MR-5, PC55MR-5 20-21

STANDARD VALUE TABLE FOR MACHINE: PC45MR-5 20 STANDARD VALUE TABLE

Machine model PC45MR-5

Engine 4D88E-7
Standard value
Item Measurement condition Unit Repair limit
for new machine
• Hydraulic oil temperature: RAISE 1.1±0.3 Max. 1.4
45 to 55 °C
• Fuel control dial: MAX
(High idle) position
• Working mode: P (Power
Mode)
• Time required to move
Blade speed blade between ground Sec.
LOWER 1.1±0.3 Max. 1.4
point and maximum
RAISE
• Measurement posture:
See “MACHINE POS-
TURE AND PROCEDURE
FOR MEASURING PER-
FORMANCE”, “Fig. 11”.
• Hydraulic oil temperature: Swing LEFT 7.0±1.5 Max. 10
45 to 55 °C
• Fuel control dial: MAX
(High idle) position
• Working mode: P (Power
Mode)
Swing speed • Time required to swing be- Sec.
tween right stroke end and Swing RIGHT 7.0±1.5 Max. 10
left stroke end
• Measurement posture:
See “MACHINE POS-
TURE AND PROCEDURE
FOR MEASURING PER-
FORMANCE”, “Fig. 12”.

Control time lag

Machine model PC45MR-5
Engine 4D88E-7
Standard value
Item Measurement condition Unit Repair limit
for new machine
• Hydraulic oil temperature: 45 to 55 °C
• Fuel control dial: MIN (Low idle) position
• Working mode: P (Power Mode)
• Set arm and bucket to OUT/DUMP stroke
Boom time lag end. Lower boom from RAISE stroke end Sec. Max. 2 Max. 3.9
and measure time required to raise ma-
chine after bucket reaches ground.
• Measurement posture: See “MACHINE
POSTURE AND PROCEDURE FOR
MEASURING PERFORMANCE”, “Fig. 13”.

20-22 PC45MR-5, PC55MR-5

20 STANDARD VALUE TABLE STANDARD VALUE TABLE FOR MACHINE: PC45MR-5

Machine model PC45MR-5

Engine 4D88E-7
Standard value
Item Measurement condition Unit Repair limit
for new machine
• Hydraulic oil temperature: 45 to 55 °C
• Fuel control dial: MIN (Low idle) position
• Working mode: P (Power Mode)
• Set boom top face horizontally and set
bucket to DUMP stroke end. Move arm IN
Arm time lag from OUT stroke end, and measure length Sec. Max. 1 Max. 2
of time until arm starts moving IN again af-
ter stopping.
• Measurement posture: See “MACHINE
POSTURE AND PROCEDURE FOR
MEASURING PERFORMANCE”, “Fig. 14”.
• Hydraulic oil temperature: 45 to 55 °C
• Fuel control dial: MIN (Low idle) position
• Working mode: P (Power Mode)
• Set boom to face horizontally and set arm
Bucket time to OUT stroke end. Curl bucket from
DUMP stroke end, and measure length of Sec. Max. 1 Max. 2
lag
time until bucket starts curling again after
stopping.
• Measurement posture: See “MACHINE
POSTURE AND PROCEDURE FOR
MEASURING PERFORMANCE”, “Fig. 15”.
• Hydraulic oil temperature: 45 to 55 °C
• Fuel control dial: MIN (Low idle) position
• Working mode: P (Power Mode)
• Lower blade from RAISE stroke end, and
Blade time lag measure time until the machine starts ris- Sec. Max. 2 Max. 3.9
ing after the blade reach ground.
• Measurement posture: See “MACHINE
POSTURE AND PROCEDURE FOR
MEASURING PERFORMANCE”, “Fig 16”.

Oil leakage
Machine model PC45MR-5
Engine 4D88E-7
Standard value
Item Measurement condition Unit Repair limit
for new machine
• Hydraulic oil temperature: 45 to 55 °C
Leakage from • Fuel control dial: MAX (High idle) position
cc/min Max. 2 Max. 10
each cylinder • Amount of the oil leak for 1 minute while
relieving the circuit for measuring

PC45MR-5, PC55MR-5 20-23

STANDARD VALUE TABLE FOR MACHINE: PC45MR-5 20 STANDARD VALUE TABLE

Pump performance
Machine model PC45MR-5
Engine 4D88E-7
Standard value
Item Measurement condition Unit Repair limit
for new machine
• Hydraulic oil temperature: 45 to 55 °C
• Engine speed: 2400 rpm
• Gear pump: No load applied
Piston pump • Test pump discharged pressure ( MPa Q Q
discharged { kg/cm2} ): P1 ℓ/min
volume (See graph.) (See graph.)
• Other pump discharged pressure ( MPa
{ kg/cm2} ): P2
• Average pump discharged pressure ( MPa
{ kg/cm2} ): (P1+P2)/2

REMARK
Avoid measuring near turning point of the graph because the error increases there.

20-24 PC45MR-5, PC55MR-5

20 STANDARD VALUE TABLE STANDARD VALUE TABLE FOR MACHINE: PC55MR-5

STANDARD VALUE TABLE FOR MACHINE: PC55MR-5

Engine speed
Machine model PC55MR-5
Engine 4D88E-7
Standard value
Item Measurement condition Unit Repair limit
for new machine
• Engine coolant temperature: 60 to 100 °C

Engine speed • Hydraulic oil temperature: 45 to 55 °C

at 1-pump re- • Fuel control dial: MAX (High idle) position Min. 2220 Min. 2220
lief • Working mode: P (Power Mode)
• Arm CURL relief
• Engine coolant temperature: 60 to 100 °C

Engine speed • Hydraulic oil temperature: 45 to 55 °C

at 2-pump re- • Fuel control dial: MAX (High idle) position Min. 2150 Min. 2150
lief • Working mode: P (Power Mode) rpm

• Arm CURL relief + Blade relief

Control valve spool stroke

Machine model PC55MR-5
Engine 4D88E-7
Standard value
Item Measurement condition Unit Repair limit
for new machine
Boom
Arm
Bucket
Swing • Spool operation of control valve unit ℓ = 30 ℓ = 30
Breaker • Measurement posture: See “MACHINE mm a=6 a=6
POSTURE AND PROCEDURE FOR
Boom swing b=6 b=6
MEASURING PERFORMANCE”, “Fig. 1”.
Blade
L.H. travel
R.H. travel

PC45MR-5, PC55MR-5 20-25

STANDARD VALUE TABLE FOR MACHINE: PC55MR-5 20 STANDARD VALUE TABLE

Stroke of control lever and pedal

Machine model PC55MR-5
Engine 4D88E-7
Standard value
Item Measurement condition Unit Repair limit
for new machine
N → Boom
Boom control
RAISE, Boom 85±10 85±10
lever
LOWER
Arm control N → Arm IN,
85±10 85±10
lever Arm OUT
N → Bucket
Bucket control
CURL, Bucket 85±10 85±10
lever
DUMP
N → Swing
Swing control
LEFT, Swing 85±10 85±10
lever • Engine: Stopped
RIGHT
• Center of lever knob
N → Swing
Boom swing • End of pedal LEFT, Swing mm 25±5 25±5
control pedal
• Read maximum value RIGHT
through travel end (exclud-
Blade control N → RAISE,
ing play at NEUTRAL). 50±5 50±5
lever LOWER
N → Travel
FORWARD,
Travel control
Travel RE- 100±10 100±10
lever
VERSE
(RIGHT/LEFT)
Work equip-
Play of control ment, Swing, Max. 5 Max. 5
lever Blade
Travel Max. 5 Max. 5

20-26 PC45MR-5, PC55MR-5

20 STANDARD VALUE TABLE STANDARD VALUE TABLE FOR MACHINE: PC55MR-5

Operating effort of control lever and pedal

Machine model PC55MR-5
Engine 4D88E-7
Standard value
Item Measurement condition Unit Repair limit
for new machine

Boom control 15.68±4.9 15.68±4.9

lever {1.6±0.5} {1.6±0.5}

Arm control 15.68±4.9 15.68±4.9

lever {1.6±0.5} {1.6±0.5}

Bucket control 15.68±4.9 15.68±4.9

lever • Hydraulic oil temperature: 45 to 55 °C {1.6±0.5} {1.6±0.5}
• Fuel control dial: MAX (High idle) position
Swing control N 15.68±4.9 15.68±4.9
lever • Hitch push-pull scale to center of lever grip
{ kg} {1.6±0.5} {1.6±0.5}
or end of pedal to measure
Boom swing • Read maximum value through travel end 78.4±19.6 78.4±19.6
control pedal {8.0±2.0} {8.0±2.0}

Blade control 29.4±9.8 29.4±9.8

lever {3.0±1.0} {3.0±1.0}

Travel control 22.5±4.9 22.5±4.9

lever {2.3±0.5} {2.3±0.5}

Work equipment, swing, boom swing, and travel oil pressures

Machine model PC55MR-5
Engine 4D88E-7
Standard value
Item Measurement condition Unit Repair limit
for new machine
• Hydraulic oil temperature: 45 to 55 °C
• Fuel control dial: MAX (High idle) position
Unload pres- • Working mode: P (Power Mode) MPa 2.94±0.49 2.94±0.49
sure • Auto-deceleration switch: OFF { kg/cm2} {30±5} {30±5}
• Each control lever and control pedal: NEU-
TRAL position
Boom relief 26.5±0.98 26.5±0.98
pressure {270±10} {270±10}

Arm relief 26.5±0.98 26.5±0.98

Boom swing { kg/cm2} 26.5±0.98 26.5±0.98

PC45MR-5, PC55MR-5 20-27

STANDARD VALUE TABLE FOR MACHINE: PC55MR-5 20 STANDARD VALUE TABLE

Machine model PC55MR-5

Engine 4D88E-7
Standard value
Item Measurement condition Unit Repair limit
for new machine

• Hydraulic oil temperature: 21.6 21.6

45 to 55 °C RAISE (+0.98/-0.49) (+0.98/-0.49)
Blade relief • Fuel control dial: MAX MPa {220 (+10/-5)} {220 (+10/-5)}
pressure (High idle) position { kg/cm2} 21.6 21.6
• Working mode: P (Power LOWER (+0.98/-0.49) (+0.98/-0.49)
Mode) {220 (+10/-5)} {220 (+10/-5)}
• Hydraulic oil temperature: 45 to 55 °C
Travel relief MPa 26.5±0.98 26.5±0.98
• Fuel control dial: MAX (High idle) position
pressure { kg/cm2} {270±10} {270±10}
• Working mode: P (Power Mode)
• Hydraulic oil temperature: 45 to 55 °C
• Fuel control dial: MAX (High idle) position
Control circuit • Working mode: P (Power Mode) MPa 4.9 (+0.59/+0.1) 4.9 (+0.59/+0.1)
oil pressure • Auto-deceleration switch: OFF { kg/cm2} {50 (+6/+1)} {50 (+6/+1)}
• Each control lever and control pedal: NEU-
TRAL position
• Hydraulic oil temperature: Each control
45 to 55 °C lever and con- 3.23±0.49 3.23±0.49
trol pedal:
• Fuel control dial: MAX {33±5} {33±5}
NEUTRAL po-
(High idle) position
LS differential sition MPa
pressure • Working mode: P (Power
{ kg/cm2}
Mode) Each control
1.57±0.1 1.57±0.1
• LS differential pressure = lever: Bucket
Pump discharged pressure CURL (with no {16±1} {16±1}
load)
- LS pressure
• Hydraulic oil temperature: When solenoid 0 0
45 to 55 °C is OFF (de-
energized) {0} {0}
• Fuel control dial: MAX
(High idle) position MPa
Solenoid valve
outlet pressure • For on/off conditions of the When solenoid { kg/cm2}
solenoid, see TESTING 2.94 (+0.49/-0.1) 2.94 (+0.49/-0.1)
is ON (ener-
AND ADJUSTING, “TEST gized) {30 (+5/-1)} {30 (+5/-1)}
OUTLET PRESSURE OF
SOLENOID VALVE”.
Each control
lever and con- 0 0
• Hydraulic oil temperature: trol pedal: {0} {0}
45 to 55 °C NEUTRAL
PPC valve out- • Fuel control dial: MAX MPa
Control lever
let pressure (High idle) position and control { kg/cm2}
• Working mode: P (Power pedal in tested 2.94 (+0.49/-0.1) 2.94 (+0.49/-0.1)
Mode) circuit: Oper- {30 (+5/-1)} {30 (+5/-1)}
ate them to
stroke end

20-28 PC45MR-5, PC55MR-5

20 STANDARD VALUE TABLE STANDARD VALUE TABLE FOR MACHINE: PC55MR-5

20 STANDARD VALUE TABLE STANDARD VALUE TABLE FOR MACHINE: PC55MR-5

Work equipment speed

Machine model PC55MR-5
Engine 4D88E-7
Standard value
Item Measurement condition Unit Repair limit
for new machine
• Hydraulic oil temperature: RAISE 2.8±0.3 Max. 3.4
45 to 55 °C
• Fuel control dial: MAX
(High idle) position
• Working mode: P (Power
Mode)
Boom speed • Time required to move Sec.
bucket teeth from ground LOWER 2.9±0.3 Max. 3.5
to RAISE stroke end
• Measurement posture:
See “MACHINE POS-
TURE AND PROCEDURE
FOR MEASURING PER-
FORMANCE”, “Fig. 8”.
• Hydraulic oil temperature: Arm IN 3.1±0.3 Max. 3.7
45 to 55 °C
• Fuel control dial: MAX
(High idle) position
• Working mode: P (Power
Mode)
Arm speed • Time required for opera- Sec.
tion between dump stroke DUMP 2.5 (+0.4/-0.2) Max. 3.0
end and arm IN stroke end
• Measurement posture:
See “MACHINE POS-
TURE AND PROCEDURE
FOR MEASURING PER-
FORMANCE”, “Fig. 9”.
• Hydraulic oil temperature: Bucket CURL 2.8±0.3 Max. 3.4
45 to 55 °C
• Fuel control dial: MAX
(High idle) position
• Working mode: P (Power
Mode)
Bucket speed • Time required for opera- Sec.
tion between dump stroke DUMP 2.0±0.3 Max. 2.4
end and arm IN stroke end
• Measurement posture:
See “MACHINE POS-
TURE AND PROCEDURE
FOR MEASURING PER-
FORMANCE”, “Fig. 10”.

PC45MR-5, PC55MR-5 20-33

STANDARD VALUE TABLE FOR MACHINE: PC55MR-5 20 STANDARD VALUE TABLE

Machine model PC55MR-5

Engine 4D88E-7
Standard value
Item Measurement condition Unit Repair limit
for new machine
• Hydraulic oil temperature: RAISE 1.3±0.3 Max. 1.6
45 to 55 °C
• Fuel control dial: MAX
(High idle) position
• Working mode: P (Power
Mode)
• Time required to move
Blade speed blade between ground Sec.
LOWER 1.3±0.3 Max. 1.6
point and maximum
RAISE
• Measurement posture:
See “MACHINE POS-
TURE AND PROCEDURE
FOR MEASURING PER-
FORMANCE”, “Fig. 11”.
• Hydraulic oil temperature: Swing LEFT 7.0±1.5 Max. 10
45 to 55 °C
• Fuel control dial: MAX
(High idle) position
• Working mode: P (Power
Mode)
Swing speed • Time required to swing be- Sec.
tween right stroke end and Swing RIGHT 7.0 (+1.8/-1.2) Max. 10
left stroke end
• Measurement posture:
See “MACHINE POS-
TURE AND PROCEDURE
FOR MEASURING PER-
FORMANCE”, “Fig. 12”.

Control time lag

Machine model PC55MR-5
Engine 4D88E-7
Standard value
Item Measurement condition Unit Repair limit
for new machine
• Hydraulic oil temperature: 45 to 55 °C
• Fuel control dial: MIN (Low idle) position
• Working mode: P (Power Mode)
• Set arm and bucket to OUT/DUMP stroke
Boom time lag end. Lower boom from RAISE stroke end Sec. Max. 2 Max. 3.9
and measure time required to raise ma-
chine after bucket reaches ground.
• Measurement posture: See “MACHINE
POSTURE AND PROCEDURE FOR
MEASURING PERFORMANCE”, “Fig. 13”.

20-34 PC45MR-5, PC55MR-5

20 STANDARD VALUE TABLE STANDARD VALUE TABLE FOR MACHINE: PC55MR-5

Machine model PC55MR-5

Oil leakage
Machine model PC55MR-5
Engine 4D88E-7
Standard value
Item Measurement condition Unit Repair limit
for new machine
• Hydraulic oil temperature: 45 to 55 °C
Leakage from • Fuel control dial: MAX (High idle) position
cc/min Max. 2 Max. 10
each cylinder • Amount of the oil leak for 1 minute while
relieving the circuit for measuring

PC45MR-5, PC55MR-5 20-35

STANDARD VALUE TABLE FOR MACHINE: PC55MR-5 20 STANDARD VALUE TABLE

Pump performance
Machine model PC55MR-5
Engine 4D88E-7
Standard value
Item Measurement condition Unit Repair limit
for new machine
• Hydraulic oil temperature: 45 to 55 °C
• Engine speed: 2400 rpm
• Gear pump: No load applied
Piston pump • Test pump discharged pressure ( MPa Q Q
discharged { kg/cm2} ): P1 ℓ/min
volume (See graph.) (See graph.)
• Other pump discharged pressure ( MPa
{ kg/cm2} ): P2
• Average pump discharged pressure ( MPa
{ kg/cm2} ): (P1+P2)/2

REMARK
Avoid measuring near turning point of the graph because the error increases there.

20-36 PC45MR-5, PC55MR-5

MACHINE POSTURE AND PROCEDURE FOR MEASURING PER-
20 STANDARD VALUE TABLE FORMANCE

MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORM-

ANCE
Fig. 1

Fig. 2

Fig. 3

Fig. 4

PC45MR-5, PC55MR-5 20-37

MACHINE POSTURE AND PROCEDURE FOR MEASURING PER-
FORMANCE 20 STANDARD VALUE TABLE

Fig. 5

Fig. 6

Fig. 7

Fig. 8

20-38 PC45MR-5, PC55MR-5

MACHINE POSTURE AND PROCEDURE FOR MEASURING PER-
20 STANDARD VALUE TABLE FORMANCE

Fig. 9

Fig. 10

Fig. 11

Fig. 12

PC45MR-5, PC55MR-5 20-39

MACHINE POSTURE AND PROCEDURE FOR MEASURING PER-
FORMANCE 20 STANDARD VALUE TABLE

Fig. 13

Fig. 14

Fig. 15

Fig. 16

20-40 PC45MR-5, PC55MR-5

30 TESTING AND ADJUSTING

PC45MR-5, PC55MR-5 30-1

CONTENTS 30 TESTING AND ADJUSTING

CONTENTS
ABBREVIATION LIST .................................................................................................................................... 30-5
RELATED INFORMATION ON TESTING AND ADJUSTING ........................................................................30-11
TOOLS FOR TESTING AND ADJUSTING.............................................................................................30-11
SKETCH OF TOOLS FOR TESTING AND ADJUSTING ...................................................................... 30-15
ENGINE AND COOLING SYSTEM.............................................................................................................. 30-17
TEST ENGINE SPEED ......................................................................................................................... 30-17
METHOD FOR TESTING ENGINE SPEED ................................................................................... 30-17
TEST EXHAUST GAS COLOR ............................................................................................................. 30-19
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER .................... 30-19
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER ...................................... 30-20
TEST AND ADJUST VALVE CLEARANCE ........................................................................................... 30-21
METHOD FOR TESTING VALVE CLEARANCE ............................................................................ 30-21
METHOD FOR ADJUSTING VALVE CLEARANCE ....................................................................... 30-22
TEST COMPRESSION PRESSURE..................................................................................................... 30-23
METHOD FOR TESTING COMPRESSION PRESSURE............................................................... 30-23
TEST ENGINE OIL PRESSURE ........................................................................................................... 30-25
METHOD FOR TESTING ENGINE OIL PRESSURE ..................................................................... 30-25
BLEED AIR FROM FUEL SYSTEM ...................................................................................................... 30-27
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM ................................................................ 30-27
TEST FUEL CIRCUIT FOR LEAKAGE ................................................................................................. 30-29
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE ........................................................... 30-29
HANDLE CYLINDER CUT-OUT MODE OPERATION........................................................................... 30-30
TEST AND ADJUST ALTERNATOR BELT TENSION ........................................................................... 30-31
METHOD FOR TESTING ALTERNATOR BELT TENSION ............................................................ 30-31
METHOD FOR ADJUSTING ALTERNATOR BELT TENSION........................................................ 30-31
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION ........................................ 30-32
METHOD FOR CHECKING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION...
................................................................................................................................................... 30-32
POWER TRAIN............................................................................................................................................ 30-34
TEST SWING CIRCLE BEARING CLEARANCE .................................................................................. 30-34
METHOD FOR TESTING SWING CIRCLE BEARING CLEARANCE ............................................ 30-34
UNDERCARRIAGE AND FRAME................................................................................................................ 30-35
TEST AND ADJUST TRACK TENSION................................................................................................ 30-35
METHOD FOR TESTING TRACK TENSION ................................................................................. 30-35
METHOD FOR ADJUSTING TRACK TENSION ............................................................................ 30-35
HYDRAULIC SYSTEM................................................................................................................................. 30-37
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM.................................................... 30-37
METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC TANK ..................... 30-37
METHOD FOR RELEASING REMAINING PRESSURE IN PPC ACCUMULATOR CIRCUIT ........ 30-37
METHOD FOR RELEASING REMAINING PRESSURE IN HYDRAULIC CYLINDER CIRCUIT .... 30-37
METHOD FOR RELEASING REMAINING PRESSURE FROM SWING MOTOR CIRCUIT........... 30-42
METHOD FOR RELEASING REMAINING PRESSURE FROM TRAVEL MOTOR CIRCUIT ......... 30-42
TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, TRAVEL, AND BOOM SWING CIRCUITS ...
.......................................................................................................................................................... 30-43
METHOD FOR TESTING OIL PRESSURE IN WORK EQUIPMENT, TRAVEL, AND BOOM SWING
CIRCUITS .................................................................................................................................. 30-43
METHOD FOR ADJUSTING OIL PRESSURE IN WORK EQUIPMENT, TRAVEL, AND BOOM SWING
CIRCUITS .................................................................................................................................. 30-52
TEST AND ADJUST SWING AND BLADE CIRCUIT OIL PRESSURE ................................................. 30-54
METHOD FOR TESTING SWING AND BLADE CIRCUIT OIL PRESSURE .................................. 30-54
METHOD FOR ADJUSTING SWING AND BLADE CIRCUIT OIL PRESSURE.............................. 30-59
TEST AND ADJUST OIL PRESSURE OF CONTROL CIRCUIT ........................................................... 30-61
METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT ............................................ 30-61
METHOD FOR ADJUSTING OIL PRESSURE OF CONTROL CIRCUIT ....................................... 30-63
ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT.............................................................. 30-65
METHOD FOR ADJUSTING OIL PRESSURE IN PUMP PC CONTROL CIRCUIT........................ 30-65

30-2 PC45MR-5, PC55MR-5

30 TESTING AND ADJUSTING CONTENTS

TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT............................................ 30-67

METHOD FOR TESTING LS DIFFERENTIAL PRESSURE BY MACHINE MONITOR .................. 30-67
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE BY TESTING TOOL .......................... 30-68
METHOD FOR ADJUSTING LS VALVE......................................................................................... 30-70
TEST OUTLET PRESSURE OF SOLENOID VALVE ............................................................................ 30-71
METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE BY MACHINE MONITOR........
................................................................................................................................................... 30-71
METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE BY TESTING TOOL...... 30-72
OPERATING CONDITION OF SOLENOID VALVE ........................................................................ 30-73
TEST PPC VALVE OUTLET PRESSURE ............................................................................................. 30-74
METHOD FOR TESTING OUTLET PRESSURE OF PPC VALVE BY MACHINE MONITOR......... 30-74
METHOD FOR TESTING OUTLET PRESSURE OF PPC VALVE BY TESTING TOOL................. 30-77
ADJUST WORK EQUIPMENT AND SWING PPC VALVES .................................................................. 30-79
METHOD FOR ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES............. 30-79
TEST SWING PARKING BRAKE RELEASE PRESSURE .................................................................... 30-80
METHOD FOR TESTING SWING PARKING BRAKE RELEASE PRESSURE WITH MACHINE MONI-
TOR............................................................................................................................................ 30-80
METHOD FOR TESTING SWING PARKING BRAKE RELEASE PRESSURE BY TESTING TOOL ........
................................................................................................................................................... 30-80
TEST AND ADJUST TRAVEL DEVIATION ........................................................................................... 30-82
METHOD FOR TESTING TRAVEL DEVIATION ............................................................................ 30-82
METHOD FOR ADJUSTING TRAVEL DEVIATION........................................................................ 30-82
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT........................................ 30-85
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BOOM CYLINDER AND
BUCKET CYLINDER.................................................................................................................. 30-85
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF ARM CYLINDER....... 30-85
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF PPC VALVE .............. 30-86
TEST OIL LEAKAGE ............................................................................................................................ 30-87
METHOD FOR TESTING OIL LEAKAGE FROM BOOM CYLINDER ............................................ 30-87
METHOD FOR TESTING OIL LEAKAGE FROM ARM CYLINDER ............................................... 30-87
METHOD FOR TESTING OIL LEAKAGE FROM BUCKET CYLINDER ......................................... 30-88
METHOD FOR TESTING OIL LEAKAGE FROM BLADE CYLINDER............................................ 30-88
BLEED AIR FROM HYDRAULIC CIRCUIT ........................................................................................... 30-90
METHOD FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT ..................................................... 30-91
PRESSURIZE HYDRAULIC TANK ....................................................................................................... 30-93
METHOD FOR PRESSURIZING HYDRAULIC TANK.................................................................... 30-93
CAB AND ITS ATTACHMENTS ................................................................................................................... 30-94
METHOD FOR OPENING AND CLOSING FLOOR UNIT ..................................................................... 30-94
METHOD FOR OPENING FLOOR UNIT ....................................................................................... 30-95
METHOD FOR CLOSING FLOOR UNIT.......................................................................................30-100
ELECTRICAL SYSTEM ..............................................................................................................................30-104
SET AND OPERATE MACHINE MONITOR.........................................................................................30-104
OPERATOR MODE .....................................................................................................................30-107
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) ..................................................30-107
CHECKING FUNCTION OF SERVICE METER ............................................................................30-107
METHOD FOR SETTING USAGE LIMITATION AND CHANGING PASSWORD ..........................30-107
SERVICE MODE...........................................................................................................................30-110
METHOD FOR OPERATING SERVICE MODE ............................................................................30-110
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION ................................ 30-111
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION .................................30-115
ABNORMALITY RECORD MENU.................................................................................................30-122
METHOD FOR CONFIRMING MAINTENANCE RECORD ...........................................................30-125
METHOD FOR OPERATING MAINTENANCE MODE SETTING..................................................30-126
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING .............................................30-130
DEFAULT MENU...........................................................................................................................30-132
DIAGNOSTIC TESTS MENU........................................................................................................30-137
ADJUSTMENT MENU ..................................................................................................................30-145
METHOD FOR OPERATING BATTERY DISCONNECT SWITCH SETTING ................................30-149

PC45MR-5, PC55MR-5 30-3

CONTENTS 30 TESTING AND ADJUSTING

S/T
Steering
STRG
SIG Signal
SOL Solenoid
STD Standard
OPT
Option
OP
PRESS Pressure
SPEC Specification
SW Switch
TEMP Temperature
T/C Torque Converter
T/M Transmission

30-10 PC45MR-5, PC55MR-5

30 TESTING AND ADJUSTING TOOLS FOR TESTING AND ADJUSTING

RELATED INFORMATION ON TESTING AND ADJUSTING

TOOLS FOR TESTING AND ADJUSTING
Tools to be used when testing the exhaust gas color
Symbol Part No. Part name Q'ty Remarks
A 799-201-9002 Handy smoke checker 1
Commercially Bosch index: 0 to 9
B Smoke meter 1
available

Tools to be used when testing and adjusting the valve clearance

Symbol Part No. Part name Q'ty Remarks
Commercially
A Mirror 1
available
Commercially
B Feeler gauge 1
available
Commercially
C Socket wrench 1 Width across flats: 22 mm
available

Tools to be used when testing the compression pressure

Symbol Part No. Part name Q'ty Remarks
A 795-502-1590 Gauge assembly 1 Pressure range: 0 to 7 MPa
YM-129A00-92
B Compression gauge adapter 1
950
C 795-101-1571 Joint 1
D 6275-11-3890 Gasket 1

Tools for testing the engine oil pressure

Symbol Part No. Part name Q'ty Remarks
- 799-101-5002 Hydraulic tester 1
A
1 799-101-5160 Nipple 1 Size: R1/8
B 790-261-1205 Digital hydraulic tester 1
C 799-401-2320 Gauge 1 Pressure range: 1 MPa

Tools to be used when testing the leakage in fuel system

Symbol Part No. Part name Q'ty Remarks
Commercially Developer for dye penetrant (color
A 1
available checker)

Tools to be used when testing the swing circle bearing clearance

Symbol Part No. Part name Q'ty Remarks
Commercially
A Dial gauge 1
available

PC45MR-5, PC55MR-5 30-11

TOOLS FOR TESTING AND ADJUSTING 30 TESTING AND ADJUSTING

Tools to be used when testing the track tension

Symbol Part No. Part name Q'ty Remarks
Commercially
A Wooden block 1
available

Tools to be used when testing and adjusting the oil pressure in work equipment circuit, travel circuit,
and boom swing circuit
Symbol Part No. Part name Q'ty Remarks
- 799-101-5002 Hydraulic tester 1
A
1 799-101-5120 Gauge 1 Pressure range: 40 MPa
B 790-261-1205 Digital hydraulic tester 1 Pressure range: 70 MPa
C 799-101-5220 Nipple 2 Size: M10x1.25 mm
D 07002-11023 O-ring 2
• Material: SS400
Commercially
E Pin 1 • Diameter: 50 mm
available
• Length: 100 mm
F 799T-404–8500 Sensor adapter 1 Pressure range: 50 MPa

Tools to be used when testing and adjusting the oil pressure in the swing circuit, and the blade circuit
Symbol Part No. Part name Q'ty Remarks
- 799-101-5002 Hydraulic tester 1
A
1 799-101-5120 Gauge 1 Pressure range: 40 MPa
B 790-261-1205 Digital hydraulic tester 1 Pressure range: 70 MPa
C 799-101-5220 Nipple 1 Size: M10x1.25 mm
D 07002-11023 O-ring 1
E 799T-404–8500 Sensor adapter 1 Pressure range: 50 MPa

Tools to be used when testing and adjusting the oil pressure in the control circuit
Symbol Part No. Part name Q'ty Remarks
- 799-101-5002 Hydraulic tester 1
A
1 799-101-5130 Gauge 1 Pressure range: 6 MPa
B 790-261-1205 Digital hydraulic tester 1 Pressure range: 70 MPa
C 799-101-5220 Nipple 1 Size: M10x1.25 mm
D 07002-11023 O-ring 1
E 799T-404–8500 Sensor adapter 1 Pressure range: 50 MPa

30-12 PC45MR-5, PC55MR-5

30 TESTING AND ADJUSTING TOOLS FOR TESTING AND ADJUSTING

Tools to be used when testing and adjusting the oil pressure in the pump LS control circuit
Symbol Part No. Part name Q'ty Remarks
- 799-101-5002 Hydraulic tester 1
A 1 799-101-5120 Gauge 2 Pressure range: 40 MPa
2 799-101-5160 Nipple 2 Size: R1/8
B 790-261-1205 Digital hydraulic tester 1 Pressure range: 70 MPa
C 799-401-3100 Adapter 1 Size: 02
D 799-401-3200 Adapter 1 Size: 03
E 799-401-2701 Differential pressure gauge 1 Pressure range: 50 MPa
F 799T-404-8500 Sensor adapter 1 Pressure range: 50 MPa

Tools to be used when testing the outlet pressure of the solenoid valve
Symbol Part No. Part name Q'ty Remarks
- 799-101-5002 Hydraulic tester 1
1 799-101-5130 Gauge 1 Pressure range: 6 MPa
A
2 799-101-5160 Nipple 1 Size: R1/8
3 790-301-1530 Elbow 1 Size: R1/8
B 790-261-1205 Digital hydraulic tester 1 Pressure range: 70 MPa
C 799-401-3100 Adapter 1 Size: 02
D 799T-404–8500 Sensor adapter 1 Pressure range: 50 MPa

Tools to be used when testing the PPC valve outlet pressure

Symbol Part No. Part name Q'ty Remarks
- 799-101-5002 Hydraulic tester 1
A 1 799-101-5130 Gauge 1 Pressure range: 6 MPa
2 799-101-5160 Nipple 1 Size: R1/8
B 790-261-1205 Digital hydraulic tester 1 Pressure range: 70 MPa
C 799-401-3100 Adapter 1 Size: 02
D 799T-404–8500 Sensor adapter 1 Pressure range: 50 MPa

Tools to be used when testing the swing parking brake release pressure
Symbol Part No. Part name Q'ty Remarks
- 799-101-5002 Hydraulic tester 1
A 1 799-101-5130 Gauge 1 Pressure range: 6 MPa
2 799-101-5160 Nipple 1 Size: R1/8
B 790-261-1205 Digital hydraulic tester 1 Pressure range: 70 MPa
C 799-401-3100 Adapter 1 Size: 02

PC45MR-5, PC55MR-5 30-13

TOOLS FOR TESTING AND ADJUSTING 30 TESTING AND ADJUSTING

Tools to be used when testing the oil leakage

Symbol Part No. Part name Q'ty Remarks
A Commercially
Measuring cylinder 1
available
B 07376-70422 Plug 1 Size: 04
C Commercially
Block 1
available

Tools to be used when bleeding air from hydraulic circuit

Symbol Part No. Part name Q'ty Remarks
Commercially
A Oil container 1
available
Commercially
B Vinyl hose 1
available

30-14 PC45MR-5, PC55MR-5

30 TESTING AND ADJUSTING SKETCH OF TOOLS FOR TESTING AND ADJUSTING

SKETCH OF TOOLS FOR TESTING AND ADJUSTING

Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.
Sensor adapter

Wiring harness

PC45MR-5, PC55MR-5 30-15

SKETCH OF TOOLS FOR TESTING AND ADJUSTING 30 TESTING AND ADJUSTING

Nipple

30-16 PC45MR-5, PC55MR-5

30 TESTING AND ADJUSTING TEST ENGINE SPEED

ENGINE AND COOLING SYSTEM

TEST ENGINE SPEED
Test this item by using the Pre-defined Monitoring or monitoring function of the machine monitor.
Check this item under the following conditions.
• Engine coolant temperature: 60 to 100 °C
• Hydraulic oil temperature: 45 to 55 °C
For testing of engine speed to perform troubleshooting or periodic maintenance, refer to this section.

METHOD FOR TESTING ENGINE SPEED

Testing engine speed at high idle
1. See “SET AND OPERATE MACHINE MONITOR” and dis-
play (01/14) “Pre-defined Mon”.
2. Set all control levers and control pedals in NEUTRAL posi-
tion, and set the lock lever in LOCK position.
3. Set the working mode to P (“Power Mode”), turn off the　
auto-deceleration, and set the travel speed setting to “Hi”.
4. Start the engine, and check the engine speed with fuel
control dial at MAX (High idle) position.
5. Set the lock lever to FREE position, and check the maxi-
mum engine speed of the time when the swing control lev-
er or the travel lever is operated gradually.
REMARK
For standard values, see STANDARD VALUE TABLE, “STANDARD VALUE TABLE FOR ENGINE”.

Testing engine speed at low idle

1. See “SET AND OPERATE MACHINE MONITOR” and dis-
play (01/14) “Pre-defined Mon”.
2. Set all control levers and control pedals in NEUTRAL posi-
tion, and set the lock lever in LOCK position.
3. Set working mode to P (“Power Mode”), turn off auto-de-
celeration.
4. Start the engine, and check the engine speed with fuel
control dial at MIN (Low idle) position.
REMARK
For standard values, see STANDARD VALUE TABLE,
“STANDARD VALUE TABLE FOR ENGINE”.

Engine speed test at 1-pump relief

1. See “SET AND OPERATE MACHINE MONITOR” and dis-
play (01/14) “Pre-defined Mon”.
2. Set all control levers and control pedals in NEUTRAL posi-
tion, and set the lock lever in LOCK position.
3. Set the working mode to P (“Power Mode”), turn off the　
auto-deceleration, and set the travel speed setting to “Hi”.
4. Start the engine, and set the fuel control dial to MAX (High
idle) position.
5. Set the work equipment lock lever in FREE position, oper-
ate R.H. work equipment control lever, and measure the
engine speed at arm CURL relief.

PC45MR-5, PC55MR-5 30-17

TEST ENGINE SPEED 30 TESTING AND ADJUSTING

REMARK
For standard values, see STANDARD VALUE TABLE, “STANDARD VALUE TABLE FOR MACHINE”.

Engine speed test at 2-pump relief

1. See “SET AND OPERATE MACHINE MONITOR” and dis-
play (01/14) “Pre-defined Mon”.
2. Set all control levers and control pedals in NEUTRAL posi-
tion, and set the lock lever in LOCK position.
3. Set the working mode to P (“Power Mode”), turn off the　
auto-deceleration, and set the travel speed setting to “Hi”.
4. Start the engine, and set the fuel control dial to MAX (High
idle) position.
5. Set the work equipment lock lever in FREE position, oper-
ate R.H. and L.H. work equipment control levers, and
measure the engine speed under the following condition.
Arm CURL relief and blade relief
REMARK
For standard values, see STANDARD VALUE TABLE, “STANDARD VALUE TABLE FOR MACHINE”.

Engine speed test at auto-deceleration

1. See “SET AND OPERATE MACHINE MONITOR” and dis-
play (01/14) “Pre-defined Mon”.
2. Set all control levers and control pedals in NEUTRAL posi-
tion, and set the lock lever in LOCK position.
3. Start the engine and set the fuel control dial to MAX (High
idle) position. Set the working mode to P (“Power Mode”),
and then turn ON auto-deceleration.
4. Check the engine speed when auto-decelerator is operat-
ed after rechecking that all control levers and control ped-
als are in NEUTRAL position.
REMARK
Engine speed drops to the speed when auto deceleration is activated if each control lever and control pedal
remain NEUTRAL for 5 seconds and longer. Check the engine speed at the time. (For detail, see STRUC-
TURE AND FUNCTION, “ENGINE SYSTEM”).
For standard values, see STANDARD VALUE TABLE, “STANDARD VALUE TABLE FOR MACHINE”.

30-18 PC45MR-5, PC55MR-5

30 TESTING AND ADJUSTING TEST EXHAUST GAS COLOR

TEST EXHAUST GAS COLOR

Tools for testing exhaust gas color
Symbol Part No. Part name Q'ty Remarks
A 799-201-9002 Handy smoke checker 1
Commercially Bosch index: 0 to 9
B Smoke meter 1
available

k Place the machine on a level ground, lower the work equipment to the ground so that it is stable, set
the lock lever to LOCK position, and stop the engine.
k Immediately after the engine is stopped, its parts and oil are still very hot, and may cause burn in-
jury. Accordingly, wait until all parts have cooled down before starting the work.
Check this item under the following conditions.
Engine coolant temperature: 60 to 100 °C
If an air source and an electric power source are not available in the field, use handy smoke checker A. When
recording official data, etc., use smoke meter B.
For testing of exhaust gas color to perform troubleshooting or periodic maintenance, refer to this section.

METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER

1. Start the engine and increase the coolant temperature into
the specified range.

2. Fit a sheet of filter paper to handy smoke checker A.

3. Insert the exhaust gas intake pipe of handy smoke checker
A into exhaust pipe (1).
4. Run the engine with fuel control dial at MAX (High idle )
and put the auto-deceleration switch to OFF position for 5
seconds. Collect the exhaust gas to the filter paper by op-
erating the handle of smoke checker A.
REMARK
Collecting time: 1.4±0.2 seconds
5. Remove the filter paper and compare it with the attached
scale for judgment.
For standard values, see STANDARD VALUE TABLE, “STANDARD VALUE TABLE FOR ENGINE”.
After finishing the test, remove the testing tools and restore the machine.

PC45MR-5, PC55MR-5 30-19

TEST EXHAUST GAS COLOR 30 TESTING AND ADJUSTING

METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER

1. Start the engine and increase the coolant temperature into
the specified range.

2. Connect the probe hose, receptacle of the accelerator

switch and air hose to smoke meter B.
REMARK
Limit the supplied air pressure to 1.47 MPa {15 kg/cm2} .
3. Connect the power cable to the electric power supply re-
ceptacle.
REMARK
Check that the power switch of smoke meter B is in OFF
position before connecting the power cable to the recepta-
cle.
4. Insert the probe of smoke meter B into the outlet of exhaust pipe (1), and fix it to the exhaust pipe with clip.
5. Loosen the cap nut (2) of the suction pump and place the filter paper.
REMARK
Place the filter paper securely so that the exhaust gas does not leak.
6. Turn ON the power switch of smoke meter B.
7. Run the engine with fuel control dial at MAX (High idle)
and put the auto-deceleration switch to OFF position. De-
press the accelerator pedal of smoke meter B for 5 sec-
onds to collect the exhaust gas on the filter paper.
8. Place the contaminated filter paper on the clean filter pa-
per (at least 10 sheets) in the filter paper holder and read
the indicated value.
For standard values, see STANDARD VALUE TABLE,
“STANDARD VALUE TABLE FOR ENGINE”.

After finishing the test, remove the testing tools and restore the machine.

30-20 PC45MR-5, PC55MR-5

30 TESTING AND ADJUSTING TEST AND ADJUST VALVE CLEARANCE

TEST AND ADJUST VALVE CLEARANCE

Tools for testing and adjusting valve clearance
Symbol Part No. Part name Q'ty Remarks
Commercially
A Mirror 1
available
Commercially
B Feeler gauge 1
available
Commercially
C Socket wrench 1 Width across flats: 22 mm
available

METHOD FOR TESTING VALVE CLEARANCE

1. Tilt open the floor frame. For details, see “HOW TO OPEN AND CLOSE FLOOR”.
2. Remove the cylinder head cover.
3. Remove the undercover, and insert socket wrench C to the center bolt of the crankshaft pulley.
4. Remove flywheel housing cap (1).

5. Rotate the crankshaft in the normal direction while watch-

ing the movement of the rocker arm of No. 1 cylinder (fly-
wheel side) and the timing scale on the flywheel. Align
stamp line (a) on the flywheel housing with stamp line (b)
of No.1/4TOP on the flywheel.
REMARK
• "1" and "4" are marked on both sides of stamp line (b).
• The stamp lines can easily be aligned by using mirror
A.
• When the piston is at the compression top dead center,
the rocker arms of both intake and exhaust valves can
be moved by the valve clearance. If they do not move,
rotate the crankshaft 1 more turn.

PC45MR-5, PC55MR-5 30-21

TEST AND ADJUST VALVE CLEARANCE 30 TESTING AND ADJUSTING

6. Insert feeler gauge B between the rocker arm and valve

%
cap to test the valve clearance.
For standard values, see STANDARD VALUE TABLE,
“STANDARD VALUE TABLE FOR ENGINE”.

After finishing the test, remove the testing tools and restore the machine.
3 Cylinder head cover mounting nut:
78.4 to 98.0 Nm {8.0 to 10 kgm}

METHOD FOR ADJUSTING VALVE CLEARANCE

Adjust the valve clearance according to the following procedure, if necessary.
1. Loosen lock nut (2) with adjustment screw (3) fixed.
2. Insert feeler gauge B between the rocker arm and valve

cap, and adjust the valve clearance with adjustment screw

(3).
REMARK
Turn adjustment screw (3) with feeler gauge B inserted,
and adjust the valve clearance until the feeler gauge B can
move lightly.

For standard value table, see STANDARD VALUE TABLE,

“STANDARD VALUE TABLE FOR ENGINE”.
3. With adjustment screw (3) fixed, tighten lock nut (2).
3 Lock nut (2):
25.48±2.94 Nm {2.6±0.3 kgm}
REMARK
• After tightening lock nut (2), check the valve clearance again.
• Apply lubricating oil to the contact faces of adjustment screw (3) and push rod.
After finishing the adjustment, restore the machine.
3 Cylinder head cover mounting nut:
78.4 to 98.0 Nm {8.0 to 10 kgm}

30-22 PC45MR-5, PC55MR-5

30 TESTING AND ADJUSTING TEST COMPRESSION PRESSURE

TEST COMPRESSION PRESSURE

Tools for testing compression pressure
Symbol Part No. Part name Q'ty Remarks
A 795-502-1590 Gauge assembly 1 Pressure range: 0 to 7 MPa
YM-129A00-92
B Compression gauge adapter 1
950
C 795-101-1571 Joint 1
D 6275-11-3890 Gasket 1

k Place the machine on a level ground, lower the work equipment to the ground so that it is stable, set
the lock lever to LOCK position, and stop the engine.
k Immediately after the engine is stopped, its parts and oil are still very hot, and may cause burn in-
jury. Accordingly, wait until all parts have cooled down before starting the work.
k When testing the compression pressure, be careful not to burn yourself by touching the exhaust
pipe, or get caught in a rotating part.
Check this item under the following conditions.
• Engine oil temperature: 40 to 60 °C
• At cranking (engine speed): 250 rpm (reference)
For testing of compression pressure to perform troubleshooting or periodic maintenance, refer to this section.

METHOD FOR TESTING COMPRESSION PRESSURE

1. Tilt open the floor frame. For details, see “HOW TO OPEN AND CLOSE FLOOR”.
2. Set the cylinders to be checked to the compression top dead center. For details, see “TEST AND ADJUST
VALVE CLEARANCE”.
REMARK
Check that both of the intake rocker arm and exhaust rocker arm are at the compression top dead center by
moving them by hand as much as the valve clearance.
3. Remove fuel high-pressure pipe (1) and holder (2), and re-
move injector (3).
4. Install gasket D to the tip of compression gauge adapter B
and insert them into the mounting part of injector (3).
5. Fix compression gauge adapter B with injector mounting
holder (2).
3 Holder mounting bolt:
25.5±2.9 Nm {2.6±0.3 kgm}
REMARK
Do not reuse the holder mounting bolt.
6. Connect compression gauge A and joint C to compression
gauge adapter B.
7. Tilt close the floor frame. For details, see “HOW TO OPEN
AND CLOSE FLOOR”.

PC45MR-5, PC55MR-5 30-23

TEST COMPRESSION PRESSURE 30 TESTING AND ADJUSTING

8. Set all the cylinders in “Cylinder Cutout Mode” by referring

to “SET AND OPERATE MACHINE MONITOR”.
k It is dangerous if all the cylinders are not set in
“Cylinder Cutout Mode” because engine will start.
Be sure to set all the cylinders in this mode.
k Make sure that all the cylinders are in the cylinder
cutout mode.
9. Measure the compression pressure when the engine is
cranked by the starting motor.
NOTICE
Do not crank the engine for 20 seconds or longer to
protect the starting motor.
REMARK
Read the compression pressure when the pointer of gauge is stabilized.
For standard values, see STANDARD VALUE TABLE, “STANDARD VALUE TABLE FOR ENGINE”.
After finishing the test, remove the testing tools and restore the machine.
Install the injectors and fuel high-pressure pipes. Start the engine and check for a fuel leak.
NOTICE
• When installing the injectors and fuel high-pressure pipes, take care that foreign materials do not
stick or enter.
• Replace the fuel high-pressure pipes with new ones.

30-24 PC45MR-5, PC55MR-5

30 TESTING AND ADJUSTING TEST ENGINE OIL PRESSURE

TEST ENGINE OIL PRESSURE

Tools for testing engine oil pressure
Symbol Part No. Part name Q'ty Remarks
- 799-101-5002 Hydraulic tester 1
A
1 799-101-5160 Nipple 1 Size: R1/8
B 790-261-1205 Digital hydraulic tester 1
C 799-401-2320 Gauge 1 Pressure range: 1 MPa

k Place the machine on a level ground, lower the work equipment to the ground so that it is stable, set
the lock lever to LOCK position, and stop the engine.
k Immediately after the engine is stopped, its parts and oil are still very hot, and may cause burn in-
jury. Accordingly, wait until all parts have cooled down before starting the work.
Check this item under the following conditions.
Engine coolant temperature: 60 to 100 °C
For testing of engine oil pressure to perform troubleshooting or periodic maintenance, refer to this section.

METHOD FOR TESTING ENGINE OIL PRESSURE

1. Open the engine rear cover.
2. Disconnect the connector from engine oil pressure switch
(1) of the cylinder block.
3. Remove engine oil pressure switch (1).

4. Install nipple A1 of hydraulic tester A and connect them to

gauge C.
5. Start the engine.

PC45MR-5, PC55MR-5 30-25

TEST ENGINE OIL PRESSURE 30 TESTING AND ADJUSTING

6. Raise engine coolant temperature to the specified range.

7. Set the working mode to P (“Power Mode”) and set each
control lever and control pedal to NEUTRAL position.
8. Measure the engine oil pressure when the fuel control dial
is at MAX (High idle) and MIN (Low idle) positions.
For standard values, see STANDARD VALUE TABLE,
“STANDARD VALUE TABLE FOR ENGINE”.

After finishing the test, remove the testing tools and restore the machine.
3 Engine oil pressure switch (1):
3.9 to 6.9 Nm {0.4 to 0.7 kgm}

30-26 PC45MR-5, PC55MR-5

30 TESTING AND ADJUSTING BLEED AIR FROM FUEL SYSTEM

BLEED AIR FROM FUEL SYSTEM

Fuel feed pump Rail pressure sensor Rail Relief valve

(mechanical)

Supply pump Main filter

Intake metering
valve

Fuel feed pump

(electromagnetic)
Fuel cooler
Pre-filter Crank speed sensor Injector

ECU
Gear speed sensor

Fuel tank Accelerator sensor

Flow of intake
Flow of injection fuel Flow of electrical signal
/return fuel

For bleeding air from fuel system to perform troubleshooting or periodic maintenance, refer to this section.

METHOD FOR BLEEDING AIR FROM FUEL SYSTEM

In the following cases, bleed air according to this procedure.
• When the fuel filter is replaced
• When fuel has run out
1. Fill the fuel tank with fuel.
2. Open the cover at the rear right of the machine.
3. Set filter vale (1) as shown in the figure.
4. Loosen air bleeding bolt (2) of the fuel prefilter by 2 to 3
turns.
5. Tighten air bleeding bolt (2) when the fuel including no air
bubbles comes out from air bleeding bolt (2).
3 bleeder bolt (2):
2.5±0.5 Nm {0.25±0.05 kgm}
6. Turn the engine starting switch to ON position.

PC45MR-5, PC55MR-5 30-27

BLEED AIR FROM FUEL SYSTEM 30 TESTING AND ADJUSTING

REMARK
The air is bled automatically in 10 to 15 seconds after the engine starting switch is turned to ON position.

30-28 PC45MR-5, PC55MR-5

30 TESTING AND ADJUSTING TEST FUEL CIRCUIT FOR LEAKAGE

TEST FUEL CIRCUIT FOR LEAKAGE

Tools for testing leakage in fuel system
Symbol Part No. Part name Q'ty Remarks
Commercially Developer for dye penetrant (color
A 1
available checker)

k Fuel leakage may result in a dangerous fire due to high pressure generated in the high-pressure cir-
cuit of the fuel system during engine operation. When checking the fuel circuit or removing the com-
ponent, check that no fuel leaks by performing the following procedure.
k Place the machine on a level ground, lower the work equipment to the ground so that it is stable, set
the lock lever to LOCK position, and stop the engine.
Clean the engine and the parts around it, and degrease them in advance so that you can easily check if there is
leakage.
For testing of fuel system for leakage to perform troubleshooting or periodic maintenance, refer to this section.

METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE

Testing method of fuel circuit for leakage at engine stopped
1. Start the engine.
2. Run the engine with fuel control dial at MIN (Low idle) position. Stop the engine after its speed is stabilized.
3. Spray the color checker A to the supply pump, common rail, injectors, and joints of the high-pressure pip-
ing.
4. Check the fuel piping and component for fuel leakage.
• Check the high-pressure circuit for fuel leakage focusing on the area where the color checker A is
sprayed.
• If there is a fuel leakage, repair it and perform the testing from step 1 again.

Testing method of fuel circuit for leakage at engine low idle

1. Start the engine.
2. Run the engine with fuel control dial at MIN (Low idle) position. Stop the engine after its speed is stabilized.
3. Spray the color checker A to the supply pump, common rail, injectors, and joints of the high-pressure pip-
ing.
4. Start the engine, and set the fuel control dial to MIN (Low idle).
5. Stop the engine and check the fuel piping and component for fuel leakage.
• Check the high-pressure circuit for fuel leakage focusing on the area where the color checker A is
sprayed.
• If there is a fuel leakage, repair it and perform the testing from step 1 again.

Testing method of fuel circuit for leakage at engine high idle

1. Start the engine.
2. Run the engine with fuel control dial at MIN (Low idle) position. Stop the engine after its speed is stabilized.
3. Spray the color checker A to the supply pump, common rail, injectors, and joints of the high-pressure pip-
ing.
4. Start the engine, and set the fuel control dial to MAX (High idle) position.
5. Stop the engine and check the fuel piping and component for fuel leakage.
• Check the high-pressure circuit for fuel leakage focusing on the area where the color checker A is
sprayed.
• If there is a fuel leakage, repair it and perform the testing from step 1 again.

PC45MR-5, PC55MR-5 30-29

HANDLE CYLINDER CUT-OUT MODE OPERATION 30 TESTING AND ADJUSTING

HANDLE CYLINDER CUT-OUT MODE OPERATION

The cylinder cutout mode operation means to run the engine with the fuel injectors of one or more cylinders
disabled electrically to reduce the number of active cylinders. The purposes and effects of cylinder cutout mode
operation are as follows.
• Cylinder cutout mode operation is used to find out a cylinder which does not output power normally (or,
combustion in it is abnormal).
• If the engine speed and output do not change from the normal operation (all-cylinder operation) when a cyl-
inder is cutout with the cylinder cutout mode operation, that cylinder has a failure.
The possible failures are as follows.
• Compression gas leakage from cylinder head gasket area
• Defective injection
• Defective piston, piston ring or cylinder liner
• Defective valve mechanism (valve operating system)
• Defective electrical system
• Common rail fuel injection system individually controls the injector of each cylinder electronically , so the
cylinder cutout test can be performed easily by the simple operations of the switches compared with the
mechanical fuel injection system. So, the defective cylinder can be found out easily.

30-30 PC45MR-5, PC55MR-5

30 TESTING AND ADJUSTING TEST AND ADJUST ALTERNATOR BELT TENSION

TEST AND ADJUST ALTERNATOR BELT TENSION

k Place the machine on a level ground, lower the work equipment completely to the ground in a stable
posture, set the lock lever to LOCK position, and then stop the engine.
For testing and adjusting the alternator belt tension to perform troubleshooting, refer to this section.

METHOD FOR TESTING ALTERNATOR BELT TENSION

When measuring the belt tension at the position (a) and (b), see “METHOD FOR OPENING AND CLOSING
FLOOR”.
Measure belt deflection at any of the positions (a) to (c) while
pressing the intermediate point of V-belt with a finger.
Belt pressing force: Approximately 98 N {Approximately 10 kg}
For standard values, see STANDARD VALUE TABLE, “STAND-
ARD VALUE TABLE FOR ENGINE”.

METHOD FOR ADJUSTING ALTERNATOR BELT TENSION

If the belt deflection is incorrect, adjust it according to the following procedure.
1. Tilt open the floor frame. For details, see “HOW TO OPEN AND CLOSE FLOOR”.
2. Loosen mounting bolts (1) and (2) and lock nut (3).
3. Turn adjustment bolt (4) and adjust the tension.
REMARK
If you turn adjustment bolt (4) clockwise, the belt tension
increases.
4. After adjusting the belt tension, tighten the mounting bolts
in the order of (2) and (1), and then tighten lock nut (3).
REMARK
Replace the V-belt if there is no clearance between the V-
belt and pulley groove bottom, or if the V-belt is scratched,
is stained with lubricating oil, or cracked.
5. After tightening adjustment bolt (4), check the belt tension again by referring to the preceding testing meth-
od.
If the belt is replaced, run the engine at low idle for at least 5 minutes to fit the belt, then test and adjust
again.
After finishing the adjustment, restore the machine.

PC45MR-5, PC55MR-5 30-31

TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TEN-
SION 30 TESTING AND ADJUSTING

TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION

k Place the machine on a level ground, lower the work equipment to the ground so that it is stable, set
the lock lever to LOCK position, and stop the engine.
For testing and adjusting the tension of air conditioner compressor belt to perform troubleshooting or periodic
maintenance, refer to this section.

METHOD FOR CHECKING AND ADJUSTING AIR CONDITIONER COMPRESSOR

BELT TENSION
(Machine with cab specification)
1. Pull engine rear cover (1) toward you to open it.
Open engine rear cover (1) fully and it is secured by rod
(2).

2. Check the belt tension of air conditioner compressor

Press the belt with a finger at a point midway between idle

pulley (3) and compressor (4). (approximately 58.8 N {ap-
proximately 6.0 kg} )
If deflection (a) is in the standard range (5 to 6 mm {0.197
to 0.236 in} ), the air conditioner compressor belt tension is
correct.

If deflection (a) is out of the standard range, adjust it according to the following procedure.
1) Loosen bolts (5) (M10, 4 pieces) and remove under-
cover (6).

30-32 PC45MR-5, PC55MR-5

TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TEN-
30 TESTING AND ADJUSTING SION

2) Loosen nut (7).

3) Adjust with adjustment nut (8) of idle pulley (3).
4) Tighten nut (7) to fix idle pulley (3).
5) Check the belt tension of air conditioner compressor
again.
If the tension is not correct, adjust it again.
6) Check each pulley for breakage and wear of the V-
groove and check the V-belts for wear.
In particular, check carefully that the V-belt is not in
contact with the V-groove bottom.
If the V-belt is stretched and has no allowance for ad-
justment, or has slipping sound or squeak because of
cuts or cracks of the belt, ask your Komatsu distributor
to replace it.
When the new V-belt is installed, readjust it after oper-
ating for 1 hour.
7) Install undercover (6) with bolts (5) (M10, 4 pieces).

3. Close engine rear cover (1).

PC45MR-5, PC55MR-5 30-33

TEST SWING CIRCLE BEARING CLEARANCE 30 TESTING AND ADJUSTING

POWER TRAIN
TEST SWING CIRCLE BEARING CLEARANCE
Tools for testing swing circle bearing clearance
Symbol Part No. Part name Q'ty Remarks
Commercially
A Dial gauge 1
available

k Do not put your hand or foot under the truck during the test.
For testing of swing circle bearing clearance to perform troubleshooting or periodic maintenance, refer to this
section.

METHOD FOR TESTING SWING CIRCLE BEARING CLEARANCE

k Place the machine on a level ground, lower the work equipment to the ground so that it is stable, set
the lock lever to LOCK position, and stop the engine.
1. Fix dial gauge A to outer race (1) or inner race (2) of the
swing circle, and put the probe to the end surface of inner
race (2) or outer race (1) on the opposite side.
Set dial gauge A in the front or rear of the machine.

2. Set the work equipment to the maximum reach posture,

and set the bucket tip to the height of the underside of the
revolving frame.
The front side of the upper structure lowers and the rear
side rises.
3. Set dial gauge A to the zero point.

4. Set the arm almost perpendicular to the ground and lower

the boom until the front part of the tracks float by 150 to
200 mm.
The front side of the upper structure rises and the rear side
lowers.
5. Read the value indicated by dial gauge A.
The value indicated by dial gauge A is the clearance of the
bearing.
6. Return the machine to the state in step 2, and check that
dial gauge A indicates 0 point again.
If the dial gauge does not indicate 0 point, repeat step 3 through 5.

30-34 PC45MR-5, PC55MR-5

30 TESTING AND ADJUSTING TEST AND ADJUST TRACK TENSION

UNDERCARRIAGE AND FRAME

TEST AND ADJUST TRACK TENSION
Testing tools for track tension
Symbol Part No. Part name Q'ty Remarks
Commercially
A Wooden block 1
available

k Place the machine on a level ground, lower the work equipment to the ground so that it is stable, set
the lock lever to LOCK position, and stop the engine.
For testing and adjusting of track tension to perform troubleshooting or periodic maintenance, refer to this sec-
tion.

METHOD FOR TESTING TRACK TENSION

1. Set the fuel control dial to MIN (Low idle), drive the machine forward by the length of track on ground, and
then slowly stop it.
2. Put a bar A on the track shoe between the idler and the
first carrier roller.
REMARK
Use an L shape steel bar, etc. which has few deformation
for bar A.
3. Measure the maximum clearance (a) between bar A and
track shoe.
Standard max. clearance (a)
• Road liner, iron shoe specification: 10 to 30 mm
• Rubber shoe specification: 1 to 3 mm

METHOD FOR ADJUSTING TRACK TENSION

If the track tension is abnormal, adjust it according to the following procedure.

Method for increasing tension

1. Pump in grease through grease fitting (1) by using a
grease gun.
2. To check if the tension is correct, run the engine with the
fuel control dial at MIN (low idle) position, move the ma-
chine slowly forward by length of track on ground, then
stop the machine.
3. After finishing adjustment, recheck that the tension is cor-
rect according to the above procedure.

PC45MR-5, PC55MR-5 30-35

TEST AND ADJUST TRACK TENSION 30 TESTING AND ADJUSTING

Method for decreasing tension

1. Loosen valve (2), remove the grease, and tighten valve
(5).
k Do not loosen the valve more than one turn, be-
cause the valve may fly out due to the high internal
pressure of the grease.
2. To check if the tension is correct, run the engine with the
fuel control dial at MIN (low idle) position, move the ma-
chine slowly forward by length of track on ground, then
stop the machine.
3. After finishing adjustment, check that the tension is correct
according to the above procedure.

30-36 PC45MR-5, PC55MR-5

30 TESTING AND ADJUSTING RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM

HYDRAULIC SYSTEM
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM
For releasing the remaining pressure from hydraulic system to perform troubleshooting periodic maintenance,
refer to this section.

METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC TANK

Release remaining pressure from the hydraulic tank according to the following procedure since hydraulic tank is
sealed and pressurized when removing a hose connected to the hydraulic tank.
1. Lower the work equipment to the ground so that it is stable, and stop the engine.
2. Remove bracket (1), and loosen oil filler cap (2) of the hy-
draulic tank gradually to release the air in the tank.

METHOD FOR RELEASING REMAINING PRESSURE IN PPC ACCUMULATOR

CIRCUIT
1. Turn the starting switch to ON position.
2. Set the lock lever to FREE position. Operate the R.H. and L.H. work equipment control levers to back and
forth, left to right for several times to release the remaining pressure in PPC accumulator circuit.

METHOD FOR RELEASING REMAINING PRESSURE IN HYDRAULIC CYLINDER

CIRCUIT
When disconnecting a pipe between a hydraulic cylinder and the control valve, release the remaining pressure
from the circuit according to the following procedure.

Method for releasing remaining pressure from machine without anti-drop valve
1. Release the remaining pressure in the hydraulic tank. See “METHOD FOR RELEASING REMAINING
PRESSURE FROM HYDRAULIC TANK”.
REMARK
Leave the oil filler cap of the hydraulic tank removed.
2. Turn the starting switch to ON position.
3. Set the lock lever to FREE position, and operate the right and left work equipment control levers forward,
backward, rightward, and leftward.
REMARK
The work equipment is operated by the pressure in PPC accumulator. Pressure in PPC accumulator is lost
by operating the work equipment 2 or 3 times.
4. Set the lock lever in LOCK position.
5. Start the engine and run it with the fuel control dial at MIN (Low idle) position for approximately 10 seconds
to increase the pressure in PPC accumulator.
6. Repeat steps 2 to 5 several times, and all remaining pressure is released from the hydraulic cylinder circuit
completely.

PC45MR-5, PC55MR-5 30-37

RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM 30 TESTING AND ADJUSTING

Method for releasing remaining pressure from machine with anti-drop valve for
boom
k Place the machine on a level ground.
k When disassembling the anti-drop valve, always release the remaining pressure in the cylinder cir-
cuit.
1. Check the function of PPC accumulator.
1) Retract arm cylinder and bucket cylinder to the stroke
ends (to set the machine in maximum reach posture),
and hold the work equipment at height (a) above the
ground.
(a) : 1.5 m
2) Keep the arm cylinder and bucket cylinder retracted to
the stroke ends, turn the starting switch to OFF posi-
tion, and stop the engine.
3) Turn the starting switch to ON position.
4) Set the lock lever to FREE position.

5) Operate the work equipment control lever fully in

30-38 PC45MR-5, PC55MR-5

30 TESTING AND ADJUSTING RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM

3. Extend the arm cylinder and bucket cylinder to the end (to
the maximum CURL position) or retract them to the end (to
the maximum DUMP position), and lower the work equip-
ment to the ground.
REMARK
Since the anti-drop valve is attached to boom cylinder bot-
tom side, hydraulic oil on bottom side of boom cylinder is
drained when work equipment is lowered to the ground,
and remaining pressure drops.
4. Turn the starting switch to OFF position.
5. Loosen the oil filler cap of the hydraulic tank gradually, and
release the air in the tank.
REMARK
Leave the oil filler cap of the hydraulic tank removed.
6. Release the remaining pressure in hydraulic cylinder cir-
cuit
1) Turn the starting switch to ON position.
2) Set the lock lever to FREE position, and operate the
right and left work equipment control levers forward,
backward, rightward, and leftward.
REMARK
The work equipment is operated by the pressure in
PPC accumulator. Pressure in PPC accumulator is
lost by operating the work equipment control levers 2
or 3 times.
3) Set the lock lever in LOCK position.
4) Start the engine and run it with the fuel control dial at MIN (Low idle) position for approximately 10 sec-
onds to increase the pressure in PPC accumulator.
7. Repeat steps 1) and 4) 4 or 5 times to release the remaining pressure from the hydraulic cylinder circuit.
k When disassembling the anti-drop valve, loosen anti-drop valve mounting bolts gradually. Make
sure that hydraulic oil pressure is released, then disassemble.

Method for releasing remaining pressure from machine with anti-drop valve for
arm in arm maximum IN posture
k Place the machine on a level ground.
k When disassembling the anti-drop valve, always release the remaining pressure in the cylinder cir-
cuit.
The following is the procedure for releasing the remaining pressure in the arm maximum IN posture.
1. Check the function of PPC accumulator
1) Retract arm cylinder and bucket cylinder to the stroke
ends (to set the machine in maximum reach posture),
and hold the work equipment at height (a) above the
ground.
(a) : 1.5 m
2) Keep the arm cylinder and bucket cylinder retracted to
the stroke ends, turn the starting switch to OFF posi-
tion, and stop the engine.
3) Turn the starting switch to ON position.
4) Set the lock lever to FREE position.

PC45MR-5, PC55MR-5 30-39

RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM 30 TESTING AND ADJUSTING

5) Operate the work equipment control levers fully in

LOWER direction and check that the work equipment
is lowered to the ground.
NOTICE
• Pressure of PPC accumulator drops gradually
after the engine stops. Be sure to perform
steps 2) to 5) in 15 seconds.
• If the work equipment is lowered or stops low-
ering the bucket halfway through the opera-
tion, pressure in PPC accumulator may be low,
and pressure cannot be released with this pro-
cedure.
REMARK
• If the work equipment is lowered by its own weight to the ground, the function of PPC accumulator
is normal.
• PPC accumulator is a periodic inspection item and an important periodic replacement part.
2. Start the engine.
3. Extend the arm cylinder to the end (to the maximum IN po-
sition), and lower the work equipment to the ground.
REMARK
• Since the anti-drop valve is attached to the arm cylin-
der head side, hydraulic oil on arm cylinder head side
is drained in this posture when work equipment is low-
ered to the ground, and remaining pressure decreases.
• The amount of oil on the head side decreases as well.
4. Turn the starting switch to OFF position.
5. Loosen the oil filler cap of the hydraulic tank gradually, and
release the air in the tank.
REMARK
Leave the oil filler cap of the hydraulic tank removed.
6. Release the remaining pressure in hydraulic cylinder circuit
1) Turn the starting switch to ON position.
2) Set the lock lever to FREE position, and operate the right and left work equipment control levers for-
ward, backward, rightward, and leftward.
REMARK
The work equipment is operated by the pressure in PPC accumulator. Pressure in PPC accumulator is
lost by operating the work equipment control levers 2 or 3 times.
3) Set the lock lever in LOCK position.
4) Start the engine and run it with the fuel control dial at MIN (Low idle) position for approximately 10 sec-
onds to increase the pressure in PPC accumulator.
7. Repeat steps 1) and 4) 4 or 5 times to release the remaining pressure from the hydraulic cylinder circuit.
k When disassembling the anti-drop valve, loosen anti-drop valve mounting bolts gradually. Make
sure that hydraulic oil pressure is released, then disassemble.

30-40 PC45MR-5, PC55MR-5

30 TESTING AND ADJUSTING RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM

Method for releasing remaining pressure from machine with anti-drop valve for
arm in arm maximum OUT posture
k Place the machine on a level ground.
k When disassembling the anti-drop valve, always release the remaining pressure in the cylinder cir-
cuit.
The following is the procedure for releasing the remaining pressure in the arm maximum OUT posture.
1. Check the function of PPC accumulator
1) Retract arm cylinder and bucket cylinder to the stroke
ends (to set the machine in maximum reach posture),
and hold the work equipment at height (a) above the
ground.
(a) : 1.5 m
2) Keep the arm cylinder and bucket cylinder retracted to
the stroke ends, turn the starting switch to OFF posi-
tion, and stop the engine.
3) Turn the starting switch to ON position.
4) Set the lock lever to FREE position.
5) Operate the work equipment control levers fully in
LOWER direction and check that the work equipment
is lowered to the ground.
NOTICE
• Pressure of PPC accumulator drops gradually
after the engine stops. Be sure to perform
steps 2) to 5) in 15 seconds.
• If the work equipment is lowered or stops low-
ering the bucket halfway through the opera-
tion, pressure in PPC accumulator may be low,
and pressure cannot be released with this pro-
cedure.
REMARK
• If the work equipment is lowered by its own weight to the ground, the function of PPC accumulator
is normal.
• PPC accumulator is a periodic inspection item and an important periodic replacement part.
2. Start the engine.
3. Retract the arm cylinder to the end (to the maximum OUT
position), and lower the work equipment to the ground.
k Since the anti-drop valve is attached to the arm cyl-
inder head side, hydraulic oil on arm cylinder head
side remains in this posture, and remaining pres-
sure increases. When releasing the remaining pres-
sure in this posture, increase the number of releas-
ing steps of releasing the remaining pressure.
4. Turn the starting switch to OFF position.
5. Loosen the oil filler cap of the hydraulic tank gradually, and
release the air in the tank.
REMARK
Leave the oil filler cap of the hydraulic tank removed.
6. Release the remaining pressure in hydraulic cylinder circuit
1) Turn the starting switch to ON position.

PC45MR-5, PC55MR-5 30-41

RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM 30 TESTING AND ADJUSTING

2) Set the lock lever to FREE position, and operate the right and left work equipment control levers for-
ward, backward, rightward, and leftward.
REMARK
The work equipment is operated by the pressure in PPC accumulator. Pressure in PPC accumulator is
lost by operating the work equipment control levers 2 or 3 times.
3) Set the lock lever in LOCK position.
4) Start the engine and run it with the fuel control dial at MIN (Low idle) position for approximately 10 sec-
onds to increase the pressure in PPC accumulator.
7. Repeat steps 1) and 4) 10 or 15 times to release the remaining pressure from the hydraulic cylinder circuit.
k When disassembling the anti-drop valve, loosen anti-drop valve mounting bolts gradually. Make
sure that hydraulic oil pressure is released, then disassemble.

METHOD FOR RELEASING REMAINING PRESSURE FROM SWING MOTOR CIR-

CUIT
When disconnecting a pipe between the swing motor and control valve, release the remaining pressure from the
circuit according to the following procedure.
1. Release the remaining pressure in the hydraulic tank. For details, see “METHOD FOR RELEASING RE-
MAINING PRESSURE FROM HYDRAULIC TANK”.
REMARK
Leave the oil filler cap of the hydraulic tank removed.
2. Turn the starting switch to ON position.
3. Set the lock lever to FREE position, and operate the right and left work equipment control levers forward,
backward, rightward, and leftward.
REMARK
The pressure in PPC accumulator is lost by operating the work equipment control lever 2 or 3 times.
4. Set the lock lever in LOCK position.
5. Start the engine and run it with the fuel control dial at MIN (Low idle) position for approximately 10 seconds
to increase the pressure in PPC accumulator.
6. Repeat steps 2 to 5 several times, and all remaining pressure is released from the swing motor circuit com-
pletely.

METHOD FOR RELEASING REMAINING PRESSURE FROM TRAVEL MOTOR

CIRCUIT
• When disconnecting a pipe between the travel motor and control valve, release the remaining pressure
from the piping according to the following procedure.
• The control valve spool of the travel motor circuit is an open circuit. Remaining pressure can be released by
performing the same operation as that described in “RELEASE REMAINING PRESSURE IN HYDRAULIC
TANK”.
1. Lower the work equipment to the ground so that it is stable, and stop the engine.
2. Remove bracket (1), and loosen oil filler cap (2) of the hy-
draulic tank gradually to release the air in the tank.

30-42 PC45MR-5, PC55MR-5

TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, TRAVEL,
30 TESTING AND ADJUSTING AND BOOM SWING CIRCUITS

TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, TRAVEL, AND

BOOM SWING CIRCUITS
Testing and adjusting tools for oil pressure in work equipment, travel, and boom swing circuits
Symbol Part No. Part name Q'ty Remarks
- 799-101-5002 Hydraulic tester 1
A
1 799-101-5120 Gauge 1 Pressure range: 40 MPa
B 790-261-1205 Digital hydraulic tester 1 Pressure range: 70 MPa
C 799-101-5220 Nipple 2 Size: M10×1.25 mm
D 07002-11023 O-ring 2
Commercially
E Pin 1 Size: Φ50 mm x 50 mm
available
F 799T-404–8500 Sensor adapter 1 Pressure range: 50 MPa

k Lower the work equipment to the ground, and stop the engine. Operate the control levers several
times to release the remaining pressure in the piping, and then loosen the oil filler cap of the hy-
draulic tank slowly to release the pressure in the tank.
Check this item under the following conditions.
Hydraulic oil temperature: 45 to 55 °C
For testing and adjusting of oil pressure in work equipment, travel, and boom swing circuits to perform trouble-
shooting or periodic maintenance, refer to this section.

METHOD FOR TESTING OIL PRESSURE IN WORK EQUIPMENT, TRAVEL, AND

BOOM SWING CIRCUITS
METHOD FOR TESTING UNLOAD PRESSURE BY MACHINE MONITOR
1. Release the remaining pressure by referring to “RELEASE REMAINING PRESSURE FROM HYDRAULIC
SYSTEM”.
2. Remove the cover at the rear left of the machine.
3. Remove the cover (1).

PC45MR-5, PC55MR-5 30-43

TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, TRAVEL,
AND BOOM SWING CIRCUITS 30 TESTING AND ADJUSTING

4. Remove the plug of pump discharge pressure pickup port

(P1) or (P2).
5. Install nipple C to pump discharged pressure pickup port
(P1) or (P2),and connect the coupling (2) or (3) of sensor
adapter F.
REMARK
• Connector (P11) side is displayed by monitoring code:
01141 “Service Press. Sens1”.
• Connector (P12) side is displayed by monitoring code:
01142 “Service Press. Sens2”.

6. Open the floor. For details, see TESTING AND ADJUST-

ING, “METHOD FOR OPENING AND CLOSING FLOOR”.
7. Connect the connector (P04) of the sensor adapter F to
the service pressure connector (P04).
8. Close the floor. For details, see TESTING AND ADJUST-
ING, “METHOD FOR OPENING AND CLOSING FLOOR”.
9. Start the engine.

10. Select and display (12/14) “Predefined Mon” or following

monitoring item on “SET AND OPERATE MACHINE MON-
ITOR”.
Monitoring code: 01141“ Service Press. Sens1”
Monitoring code: 01142“ Service Press. Sens2”
11. Adjust the hydraulic oil temperature within the specified
range.
12. Set the working mode to P (“Power Mode”).
13. Turn off the auto-deceleration.
14. Start the engine to increase the hydraulic oil temperature
to 45 to 55 °C.
15. Set all the control levers and control pedals to NEUTRAL position.
16. Check that each control lever and pedal are in NEUTRAL, turn the fuel control dial to MAX (High idle) posi-
tion, and check the oil pressure.
The unloaded pressure of the unload valve is displayed.
For standard values, see “STANDARD VALUE TABLE, STANDARD VALUE TABLE FOR MACHINE”.
After finishing the test, remove the testing tools and restore the machine.

METHOD FOR TESTING UNLOAD PRESSURE BY TESTING TOOLS

1. Release the remaining pressure. For details, see “RELEASE REMAINING PRESSURE FROM HYDRAUL-
IC SYSTEM”.

30-44 PC45MR-5, PC55MR-5

TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, TRAVEL,
30 TESTING AND ADJUSTING AND BOOM SWING CIRCUITS

2. Remove the cover at the rear left of the machine.

3. Remove cover (1).

4. Install nipple C to pump discharged pressure pickup port

(P1) or (P2), and connect gauge A1 of hydraulic tester A.
REMARK
Gauge in digital hydraulic tester B can also be used in
place of gauge A1.
5. Set working mode to P (“Power Mode”), turn off auto-de-
celeration.
6. Start the engine to increase the hydraulic oil temperature
to 45 to 55 °C.
7. Set each control lever and control pedal to NEUTRAL po-
sition.
8. Check that each control lever and pedal are in NEUTRAL,
set the fuel control dial to MAX (High idle) position, and
check the oil pressure.
The unloaded pressure of the unload valve is displayed.
For standard values, see STANDARD VALUE TABLE,
“STANDARD VALUE TABLE FOR MACHINE”.

After finishing the test, remove the testing tools and restore the machine.

METHOD FOR TESTING WORK EQUIPMENT RELIEF PRESSURE BY MACHINE

MONITOR
1. Release the remaining pressure by referring to “RELEASE REMAINING PRESSURE FROM HYDRAULIC
SYSTEM”.
2. Remove the cover at the rear left of the machine.

PC45MR-5, PC55MR-5 30-45

TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, TRAVEL,
AND BOOM SWING CIRCUITS 30 TESTING AND ADJUSTING

3. Remove the cover (1).

4. Remove the plug of pump discharge pressure pickup port

6. Open the floor. For details, see TESTING AND ADJUST-

10. Select and display (12/14) “Predefined Mon” or following

30-46 PC45MR-5, PC55MR-5

TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, TRAVEL,
30 TESTING AND ADJUSTING AND BOOM SWING CIRCUITS

Relieved pressure of the main relief valve for work equipment and travel circuits is displayed.
For standard values, see “STANDARD VALUE TABLE, STANDARD VALUE TABLE FOR MACHINE”.
After finishing the test, remove the testing tools and restore the machine.

METHOD FOR TESTING WORK EQUIPMENT RELIEF PRESSURE BY TESTING

TOOLS
1. Release the remaining pressure. For details, see “RELEASE REMAINING PRESSURE FROM HYDRAUL-
IC SYSTEM”.
2. Remove the cover at the rear left of the machine.
3. Remove cover (1).

4. Install nipple C to pump discharged pressure pickup port

(P1) or (P2), and connect gauge A1 of hydraulic tester A.
REMARK
Gauge in digital hydraulic tester B can also be used in
place of gauge A1.
5. Set the working mode to P (“Power Mode”) mode.
6. Start the engine to increase the hydraulic oil temperature
to 45 to 55 °C.
7. Operate the cylinder to check (boom, arm, or bucket) to
the stroke end.
8. Set the fuel control dial in MAX (High idle) position and
measure the oil pressure when the work equipment circuit
to be checked is relieved.
Relieved pressure of the main relief valve for work equip-
ment and travel circuits is displayed.
For standard values, see STANDARD VALUE TABLE,
“STANDARD VALUE TABLE FOR MACHINE”.

After finishing the test, remove the testing tools and restore the machine.

PC45MR-5, PC55MR-5 30-47

TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, TRAVEL,
AND BOOM SWING CIRCUITS 30 TESTING AND ADJUSTING

METHOD FOR TESTING TRAVEL RELIEF PRESSURE BY MACHINE MONITOR

1. Release the remaining pressure by referring to “RELEASE REMAINING PRESSURE FROM HYDRAULIC
SYSTEM”.
2. Remove the cover at the rear left of the machine.
3. Remove the cover (1).

4. Remove the plug of pump discharge pressure pickup port

6. Open the floor. For details, see TESTING AND ADJUST-

30-48 PC45MR-5, PC55MR-5

TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, TRAVEL,
30 TESTING AND ADJUSTING AND BOOM SWING CIRCUITS

10. Select and display (12/14) “Predefined Mon” or following

13. Insert the pin E between the sprocket and the track frame
to securely lock the track.
14. Turn the fuel control dial in MAX (High idle) position and
measure the oil pressure at travel relief.
k Before operating the travel lever and the pedal,
check the sprocket position locked with pin and
locked direction of the travel again.
Relieved pressure of the main relief valve for work equip-
ment and travel circuits is displayed.
For standard values, see “STANDARD VALUE TABLE,
STANDARD VALUE TABLE FOR MACHINE”.
After finishing the test, remove the testing tools and restore the machine.

METHOD FOR TESTING TRAVEL RELIEF PRESSURE BY TESTING TOOLS

1. Release the remaining pressure. For details, see “RELEASE REMAINING PRESSURE FROM HYDRAUL-
IC SYSTEM”.
2. Remove the cover at the rear left of the machine.
3. Remove cover (1).

PC45MR-5, PC55MR-5 30-49

TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, TRAVEL,
AND BOOM SWING CIRCUITS 30 TESTING AND ADJUSTING

4. Install nipple C to pump discharged pressure pickup port

(P1) or (P2), and connect gauge A1 of hydraulic tester A.
REMARK
Gauge in digital hydraulic tester B can also be used in
place of gauge A1.
5. Set the working mode to P (“Power Mode”) mode.
6. Start the engine to increase the hydraulic oil temperature
to 45 to 55 °C.
7. Insert pin E between the sprocket and the track frame to
securely lock the track.
8. Set the fuel control dial in MAX (High idle) position and
measure the oil pressure at travel relief.
k Before operating the travel lever and pedal, check
the sprocket position locked with pin and locked
direction of the travel again.
Relieved pressure of the main relief valve for work equip-
ment and travel circuits is displayed.
For standard values, see STANDARD VALUE TABLE,
“STANDARD VALUE TABLE FOR MACHINE”.

After finishing the test, remove the testing tools and restore the machine.

METHOD FOR TESTING BOOM SWING RELIEF PRESSURE BY MACHINE MONI-

TOR
1. Release the remaining pressure by referring to “RELEASE REMAINING PRESSURE FROM HYDRAULIC
SYSTEM”.
2. Remove the cover at the rear left of the machine.

30-50 PC45MR-5, PC55MR-5

TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, TRAVEL,
30 TESTING AND ADJUSTING AND BOOM SWING CIRCUITS

3. Remove the cover (1).

4. Remove the plug of pump discharge pressure pickup port

6. Open the floor. For details, see TESTING AND ADJUST-

10. Select and display (12/14) “Predefined Mon” or following

PC45MR-5, PC55MR-5 30-51

TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, TRAVEL,
AND BOOM SWING CIRCUITS 30 TESTING AND ADJUSTING

METHOD FOR TESTING BOOM SWING RELIEF PRESSURE BY TESTING TOOLS

1. Release the remaining pressure. For details, see “RELEASE REMAINING PRESSURE FROM HYDRAUL-
IC SYSTEM”.
2. Remove the cover at the rear left of the machine.
3. Remove cover (1).

4. Install nipple C to pump discharged pressure pickup port

(P1) or (P2), and connect gauge A1 of hydraulic tester A.
REMARK
Gauge in digital hydraulic tester B can also be used in
place of gauge A1.
5. Set the working mode to P (“Power Mode”) mode.
6. Start the engine to increase the hydraulic oil temperature
to 45 to 55 °C.
7. Depress the boom swing control pedal. Operate the boom
swing cylinder to the stroke end.
8. Set the fuel control dial in MAX (High idle) position and
measure the oil pressure at swing relief.
Relieved pressure of the main relief valve for work equip-
ment and travel circuits is displayed.
For standard values, see STANDARD VALUE TABLE,
“STANDARD VALUE TABLE FOR MACHINE”.

After finishing the test, remove the testing tools and restore the machine.

METHOD FOR ADJUSTING OIL PRESSURE IN WORK EQUIPMENT, TRAVEL,

AND BOOM SWING CIRCUITS

30-52 PC45MR-5, PC55MR-5

TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, TRAVEL,
30 TESTING AND ADJUSTING AND BOOM SWING CIRCUITS

METHOD FOR ADJUSTING UNLOAD PRESSURE

The unload valve (unload pressure) cannot be adjusted.

METHOD FOR ADJUSTING OIL WORK EQUIPMENT, TRAVEL, AND BOOM

SWING RELIEF PRESSURE
If the work equipment, travel, and boom swing relief pressures
are abnormal, adjust main relief valve (1) according to the fol-
lowing procedure.
REMARK
(a) in the figure is installed in only 9-spool valve specification.

1. Tilt open the floor frame. For details, see “HOW TO OPEN AND CLOSE FLOOR”.
2. Loosen lock nut (2).
3. Turn adjustment screw (3) to adjust oil pressure.
REMARK
• Turn adjustment screw (3) clockwise to raise the pres-
sure. Turn the screw counterclockwise to lower the
pressure.
• Pressure adjustment for 1 turn of adjustment screw
(3): Approximately 12.6 MPa {Approximately
128 kg/cm2}
k Do not turn adjustment screw (3) counterclockwise
more than 1 turn because it may fly out.
4. After adjusting pressure, tighten lock nut (2).
3 Locknut (2):
39 to 49 Nm {4 to 5 kgm}
After the adjustment, recheck the oil pressure according to the testing procedure described above.

PC45MR-5, PC55MR-5 30-53

TEST AND ADJUST SWING AND BLADE CIRCUIT OIL PRESSURE 30 TESTING AND ADJUSTING

TEST AND ADJUST SWING AND BLADE CIRCUIT OIL PRESSURE

Tools for testing and adjusting oil pressure in swing and blade circuits
Symbol Part No. Part name Q'ty Remarks
- 799-101-5002 Hydraulic tester 1
A
1 799-101-5120 Gauge 1 Pressure range: 40 MPa
B 790-261-1205 Digital hydraulic tester 1 Pressure range: 70 MPa
C 799-101-5220 Nipple 1 Size: M10×1.25 mm
D 07002-11023 O-ring 1
E 799T-404–8500 Sensor adapter 1 Pressure range: 50 MPa

k Lower the work equipment to the ground, and stop the engine. Operate the control levers several
times to release the remaining pressure in the piping, and then loosen the oil filler cap of the hy-
draulic tank slowly to release the pressure in the tank.
Check this item under the following conditions.
Hydraulic oil temperature: 45 to 55 °C
For testing and adjusting of oil pressure in swing and blade circuits to perform troubleshooting or periodic main-
tenance, refer to this section.

METHOD FOR TESTING SWING AND BLADE CIRCUIT OIL PRESSURE

METHOD FOR TESTING SWING RELIEF PRESSURE BY MACHINE MONITOR
1. Release the remaining pressure by referring to “RELEASE REMAINING PRESSURE FROM HYDRAULIC
SYSTEM”.
2. Remove the cover at the rear left of the machine.
3. Remove the cover (1).

30-54 PC45MR-5, PC55MR-5

30 TESTING AND ADJUSTING TEST AND ADJUST SWING AND BLADE CIRCUIT OIL PRESSURE

4. Install the nipple C to the gear pump discharge port (P3).

Then, connect the coupling (2) or (3) of sensor adapter E.
REMARK
• Connector (P11) side is displayed by monitoring code:
01141 “Service Press. Sens1”.
• Connector (P12) side is displayed by monitoring code:
01142 “Service Press. Sens2”.

5. Open the floor. For details, see TESTING AND ADJUST-

ING, “METHOD FOR OPENING AND CLOSING FLOOR”.
6. Connect the connector (P04) of the sensor adapter E to
the service pressure connector (P04).
7. Close the floor. For details, see TESTING AND ADJUST-
ING, “METHOD FOR OPENING AND CLOSING FLOOR”.
8. Start the engine.

9. Select and display (12/14) “Predefined Mon” or following

monitoring item on “SET AND OPERATE MACHINE MON-
ITOR”.
Monitoring code: 01141“ Service Press. Sens1”
Monitoring code: 01142“ Service Press. Sens2”
10. Adjust the hydraulic oil temperature within the specified
range.
11. Set the working mode to P (“Power Mode”).
12. Turn the fuel control dial in MAX (High idle) position, re-
lieve the left and right swing circuit with the swing control
lever, and test the oil pressure.
k When relieving the swing circuit with the swing control lever, securely lock the upper structure
by using the work equipment.
The set pressure of the swing motor safety valve is lower than that of the main relief valve. If the swing
circuit is relieved, the set pressure of the safety valve is the same as the set pressure of the safety valve.
For standard values, see “STANDARD VALUE TABLE, STANDARD VALUE TABLE FOR MACHINE”.
After finishing the test, remove the testing tools and restore the machine.

METHOD FOR TESTING SWING RELIEF PRESSURE BY TESTING TOOLS

1. Release the remaining pressure. For details, see “RELEASE REMAINING PRESSURE FROM HYDRAUL-
IC SYSTEM”.

PC45MR-5, PC55MR-5 30-55

TEST AND ADJUST SWING AND BLADE CIRCUIT OIL PRESSURE 30 TESTING AND ADJUSTING

2. Remove the cover at the rear left of the machine.

3. Remove cover (1).

4. Install nipple C to gear pump discharged port (P3), and

connect gauge A1 of hydraulic tester A.
REMARK
Gauge in digital hydraulic tester B can also be used in
place of gauge A1.
5. Set working mode to P (“Power Mode”), turn off auto-de-
celeration.
6. Start the engine to increase the hydraulic oil temperature
to 45 to 55 °C.
7. Set the fuel control dial in MAX (High idle) position, per-
form right or left swing relief, and measure the oil pressure.
k When performing swing relief by operating the
swing control lever, lock the machine securely by
using the work equipment.
Set pressure of swing motor safety valve is lower than the
set pressure of main relief valve. Increase the set pressure
by performing swing relief.
For standard values, see STANDARD VALUE TABLE,
“STANDARD VALUE TABLE FOR MACHINE”.

After finishing the test, remove the testing tools and restore the machine.

METHOD FOR TESTING BLADE RELIEF PRESSURE BY MACHINE MONITOR

1. Release the remaining pressure by referring to “RELEASE REMAINING PRESSURE FROM HYDRAULIC
SYSTEM”.
2. Remove the cover at the rear left of the machine.

30-56 PC45MR-5, PC55MR-5

30 TESTING AND ADJUSTING TEST AND ADJUST SWING AND BLADE CIRCUIT OIL PRESSURE

3. Remove the cover (1).

4. Remove the plug of gear pump discharge pressure pickup

port (P3).
5. Install nipple C to gear pump discharge pressure pickup
port (P3),and connect the coupling (2) or (3) of sensor
adapter E.
REMARK
• Connector (P11) side is displayed by monitoring code:
01141 “Service Press. Sens1”.
• Connector (P12) side is displayed by monitoring code:
01142 “Service Press. Sens2”.

6. Open the floor. For details, see TESTING AND ADJUST-

ING, “METHOD FOR OPENING AND CLOSING FLOOR”.
7. Connect the connector (P04) of the sensor adapter E to
the service pressure connector (P04).
8. Close the floor. For details, see TESTING AND ADJUST-
ING, “METHOD FOR OPENING AND CLOSING FLOOR”.
9. Start the engine.

10. Select and display (12/14) “Predefined Mon” or following

PC45MR-5, PC55MR-5 30-57

TEST AND ADJUST SWING AND BLADE CIRCUIT OIL PRESSURE 30 TESTING AND ADJUSTING

For standard values, see “STANDARD VALUE TABLE, STANDARD VALUE TABLE FOR MACHINE”.
After finishing the test, remove the testing tools and restore the machine.

METHOD FOR TESTING BLADE RELIEF PRESSURE BY TESTING TOOLS

1. Release the remaining pressure. For details, see “RELEASE REMAINING PRESSURE FROM HYDRAUL-
IC SYSTEM”.
2. Remove the cover at the rear left of the machine.
3. Remove cover (1).

4. Install nipple C to gear pump discharged port (P3), and

connect gauge A1 of hydraulic tester A.
REMARK
Gauge in digital hydraulic tester B can also be used in
place of gauge A1.
5. Set the working mode to P (“Power Mode”) mode.
6. Start the engine to increase the hydraulic oil temperature
to 45 to 55 °C.
7. Operate the blade to the stroke end.
8. Set the fuel control dial in MAX (High idle) position, and
measure the oil pressure when the blade circuit is relieved.
For standard values, see STANDARD VALUE TABLE,
“STANDARD VALUE TABLE FOR MACHINE”.

After finishing the test, remove the testing tools and restore the machine.

30-58 PC45MR-5, PC55MR-5

30 TESTING AND ADJUSTING TEST AND ADJUST SWING AND BLADE CIRCUIT OIL PRESSURE

METHOD FOR ADJUSTING SWING AND BLADE CIRCUIT OIL PRESSURE

METHOD FOR ADJUSTING SWING RELIEF PRESSURE
If the swing relief pressure is abnormal, adjust safety valve (1)
of the swing motor according to the following procedure.

1. Check that the blade relief pressure is normal.

2. Tilt open the floor frame. For details, see “HOW TO OPEN AND CLOSE FLOOR”.
3. Loosen lock nut (2) of safety valve (1) and turn end cap (adjustment screw) (3) to adjust the pressure.
k Do not turn end cap (adjustment screw) (3) counterclockwise more than 1 turn because it may fly
out.
NOTICE
• If end cap (adjustment screw) (3) is turned clockwise, the pressure increases.
• If end cap (adjustment screw) (3) is turned counterclockwise, the pressure decreases.
Quantity of adjustment per turn of end cap (adjustment nut) (3): 17.4 MPa {178 kg/cm2}
4. After adjusting, tighten lock nut (2) with end cap (adjust-
ment screw) (3) fixed.
3 Locknut (2):
93.2 to 117.7 Nm {9.5 to 12 kgm}

After the adjustment, recheck the oil pressure according to the testing procedure described above.

METHOD FOR ADJUSTING BLADE RELIEF PRESSURE

If the blade relief pressure is abnormal, adjust relief valve (4)
according to the following procedure.
REMARK
If the blade relief pressure is below the set swing relief pres-
sure, the swing relief pressure decreases as well.

PC45MR-5, PC55MR-5 30-59

TEST AND ADJUST SWING AND BLADE CIRCUIT OIL PRESSURE 30 TESTING AND ADJUSTING

1. Loosen lock nut (5) of main relief valve (4) and turn end
cap (adjustment screw) (6) to adjust the pressure.
k Do not turn end cap (adjustment screw) (6) counter-
clockwise more than 1 turn. If it is turned more, it
may fly out.
REMARK
• If end cap (adjustment screw) (6) is turned clockwise,
the pressure increases.
• If end cap (adjustment screw) (6) is turned counter-
clockwise, the pressure decreases.
Quantity of adjustment per turn of end cap (adjustment nut) (6): 19.6 MPa {200 kg/cm2}
2. After adjusting, tighten lock nut (5) with end cap (adjustment screw) (6) fixed.
3 Locknut (5):
39 to 49 Nm {4 to 5 kgm}
After the adjustment, recheck the oil pressure according to the testing procedure described above.

30-60 PC45MR-5, PC55MR-5

30 TESTING AND ADJUSTING TEST AND ADJUST OIL PRESSURE OF CONTROL CIRCUIT

TEST AND ADJUST OIL PRESSURE OF CONTROL CIRCUIT

Testing and adjusting tools for oil pressure in control circuit
Symbol Part No. Part name Q'ty Remarks
- 799-101-5002 Hydraulic tester 1
A
1 799-101-5130 Gauge 1 Pressure range: 6 MPa
B 790-261-1205 Digital hydraulic tester 1 Pressure range: 70 MPa
C 799-101-5220 Nipple 1 Size: M10x1.25 mm
D 07002-11023 O-ring 1
E 799T-404–8500 Sensor adapter 1 Pressure range: 50 MPa

k Lower the work equipment to the ground, and stop the engine. Operate the control levers several
times to release the remaining pressure in the piping, and then loosen the oil filler cap of the hy-
draulic tank slowly to release the pressure in the tank.
Check this item under the following conditions.
Hydraulic oil temperature: 45 to 55 °C
For testing and adjusting of control circuit pressure to perform troubleshooting or periodic maintenance, refer to
this section.

METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT

METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT BY MACHINE
MONITOR
1. Release the remaining pressure by referring to “RELEASE REMAINING PRESSURE FROM HYDRAULIC
SYSTEM”.
2. Remove the cover on the rear L.H side of the machine.
3. Remove the cover (1).

4. Remove the plug of pilot pump pressure pickup port (1).

PC45MR-5, PC55MR-5 30-61

TEST AND ADJUST OIL PRESSURE OF CONTROL CIRCUIT 30 TESTING AND ADJUSTING

5. Install the nipple C, and connect the coupling (2) or (3) of

sensor adapter E.
REMARK
• Connector (P11) side is displayed by monitoring code:
01141 “Service Press. Sens1”.
• Connector (P12) side is displayed by monitoring code:
01142 “Service Press. Sens2”.
6. Open the floor. See “METHOD FOR OPENING AND
CLOSING FLOOR”.
7. Connect the connector (P04) of the sensor adapter E to
the service pressure connector (P04).
8. Start the engine.

9. Select and display (12/14) “Predefined Mon” or following

METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT BY TESTING

TOOLS
1. Release the remaining pressure. For details, see “RELEASE REMAINING PRESSURE FROM HYDRAUL-
IC SYSTEM”.
2. Remove the cover at the rear left of the machine.
3. Remove cover (1).

30-62 PC45MR-5, PC55MR-5

30 TESTING AND ADJUSTING TEST AND ADJUST OIL PRESSURE OF CONTROL CIRCUIT

4. Install nipple C to pilot pump pressure output port (1), and

After finishing the test, remove the testing tools and restore the machine.

METHOD FOR ADJUSTING OIL PRESSURE OF CONTROL CIRCUIT

If the oil pressure in the control circuits is abnormal, adjust con-
trol relief valve (2) according to the following procedure.

1. Tilt open the floor frame. For details, see “HOW TO OPEN AND CLOSE FLOOR”.

PC45MR-5, PC55MR-5 30-63

TEST AND ADJUST OIL PRESSURE OF CONTROL CIRCUIT 30 TESTING AND ADJUSTING

2. Loosen lock nut (3) of relief valve (2) and turn adjustment
screw (4) to adjust.
REMARK
• If adjustment screw (4) is turned clockwise, the pres-
sure increases.
• If adjustment screw (4) is turned counterclockwise, the
pressure decreases.
Quantity of adjustment per turn of adjustment screw (4):
0.92 MPa {9.4 kg/cm2}
3. After adjusting, tighten lock nut (3) with adjustment screw
(4) fixed.
3 Locknut (3):
9.8 Nm {1.0 kgm}
4. Tilt close the floor frame. For details, see “HOW TO OPEN AND CLOSE FLOOR”.
After the adjustment, recheck the oil pressure according to the testing procedure described above.

30-64 PC45MR-5, PC55MR-5

30 TESTING AND ADJUSTING ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT

ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT

NOTICE
Before starting the adjustment, check the oil pressures of following circuits are normal (work equip-
ment, travel, boom swing, and control).
Perform this adjustment item under the following conditions.
Hydraulic oil temperature: 45 to 55 °C
For adjusting of pump PC control circuit oil pressure to perform troubleshooting, refer to this section.

METHOD FOR ADJUSTING OIL PRESSURE IN PUMP PC CONTROL CIRCUIT

When the phenomena shown below occur and PC valve (1)
seems to be defective, adjust it according to the following pro-
cedure.
• When the working load increases, the engine speed drops
largely.
• The engine speed is normal but the work equipment speed
is low.
NOTICE
Do not turn the lock nuts and adjustment screws other
than the lock nut for adjusting PC-valve (1), since they af-
fect the hydraulic pump performance.
REMARK
The width across flats of lock nut (2) for PC valve (1) is 19 mm, and the width across flats (inside) of the adjust-
ment screw (3) is 5 mm.
1. Put a matchmark on the end surface of adjustment screw
(3) and valve body.
REMARK
Put matchmark (b) to indicate the position before adjust-
ment so that you can return the adjustment screw to the
original position if you turn it in the opposite direction.
2. Loosen lock nut (2).
3. Turn adjustment screw (3) to adjust oil pressure.
NOTICE
The turning direction changes depends on the posi-
tion of punch mark (a) because of the eccentric cam
adjustment screw (3). Structurally, adjustable range of
adjustment screw (3) is within 180 ° however actual ad-
justable range of the screw is within 90 ° when turning
the screw clockwise and counterclockwise.
• When the work equipment speed is low, turn adjust-
ment screw (3) in the direction to increase the pump
absorption torque.
• When the engine speed is low, turn adjustment screw
(3) in the direction to decrease the pump absorption
torque.

Adjustable range of adjustment screw (3)

Mark (a) made before adjustment Within range of (e) in figure Within range of (f) in figure
Turn the screw counterclockwise
Pump absorption torque decreases Pump absorption torque increases
within a range of 90 °.

PC45MR-5, PC55MR-5 30-65

ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT 30 TESTING AND ADJUSTING

Mark (a) made before adjustment Within range of (e) in figure Within range of (f) in figure
Turn the screw clockwise within a
Pump absorption torque increases Pump absorption torque decreases
range of 90 °.
4. With adjustment screw (3) fixed, tighten lock nut (2).
3 Locknut (2):
27.4 to 34.4 Nm {2.8 to 3.5 kgm}

30-66 PC45MR-5, PC55MR-5

30 TESTING AND ADJUSTING TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT

TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT

Testing and adjusting tools for oil pressure in pump LS control circuit
Symbol Part No. Part name Q'ty Remarks
- 799-101-5002 Hydraulic tester 1
A 1 799-101-5120 Gauge 2 Pressure range: 40 MPa
2 799-101-5160 Nipple 2 Size: R1/8
B 790-261-1205 Digital hydraulic tester 1 Pressure range: 70 MPa
C 799-401-3100 Adapter 1 Size: 02
D 799-401-3200 Adapter 1 Size: 03
E 799-401-2701 Differential pressure gauge 1 Pressure range: 50 MPa
F 799T-404–8500 Sensor adapter 1 Pressure range: 50 MPa

k Lower the work equipment to the ground, and stop the engine. Operate the control levers several
times to release the remaining pressure in the piping, and then loosen the oil filler cap of the hy-
draulic tank slowly to release the pressure in the tank.
NOTICE
Before starting the test, check that the oil pressures in the work equipment, travel, boom swing, and
control circuits are normal.
Check this item under the following conditions.
Hydraulic oil temperature: 45 to 55 °C
For testing and adjusting of oil pressure in pump LS control circuit to perform troubleshooting or periodic mainte-
nance, refer to this section.

METHOD FOR TESTING LS DIFFERENTIAL PRESSURE BY MACHINE MONITOR

1. Release the remaining pressure by referring to “RELEASE REMAINING PRESSURE FROM HYDRAULIC
SYSTEM”.
2. Remove the cover at the rear left of the machine.
3. Remove the cover (1).

4. Disconnect the hose (2) (pump discharge pressure side)

and the hose (3) (LS pressure side).
5. Connect the adapter C to the pump discharge pressure
side, and the adapter D to the LS pressure side.

PC45MR-5, PC55MR-5 30-67

TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT 30 TESTING AND ADJUSTING

6. Install the nipple A2 to the adapter C, and D. Then, con-

nect the coupling (4) or (5) of sensor adapter F.
REMARK
• Connector (P11) side is displayed by monitoring code:
01141 “Service Press. Sens1”.
• Connector (P12) side is displayed by monitoring code:
01142 “Service Press. Sens2”.
7. Open the floor. For details, see TESTING AND ADJUST-
ING, “METHOD FOR OPENING AND CLOSING FLOOR”.
8. Connect the connector (P04) of the sensor adapter F to
the service pressure connector (P04).
9. Close the floor. For details, see TESTING AND ADJUST-
ING, “METHOD FOR OPENING AND CLOSING FLOOR”.
10. Start the engine.

11. Select and display (12/14) “Predefined Mon” or following

monitoring item on “SET AND OPERATE MACHINE MON-
ITOR”.
Monitoring code: 01141“ Service Press. Sens1”
Monitoring code: 01142“ Service Press. Sens2”
12. Adjust the hydraulic oil temperature within the specified
range.
13. Set all the control levers and the control pedals in NEU-
TRAL position, and set the lock lever in OFF position.

14. Operate the work equipment and move the cylinders as

follows.
• Boom cylinder: Fully extended
• Arm cylinder: Fully retracted
• Bucket cylinder: Fully retracted
15. Turn the fuel control dial in MAX (High idle) position, and
measure the pump discharge pressure and LS pressure
(actuator load pressure) simultaneously when each control
lever and control pedal are in NEUTRAL position or bucket
CURL control lever is moved to full stroke position.
REMARK
Calculating LS differential pressure: LS differential pressure = Pump discharge pressure - LS pressure
For standard values, see “STANDARD VALUE TABLE, STANDARD VALUE TABLE FOR MACHINE”.
After finishing the test, remove the testing tools and restore the machine.

METHOD FOR TESTING LS DIFFERENTIAL PRESSURE BY TESTING TOOL

To obtain the LS differential pressure, measure the pump discharged pressure and LS pressure (actuator load
pressure) simultaneously, and calculate the difference.
1. Release the remaining pressure. For details, see “RELEASE REMAINING PRESSURE FROM HYDRAUL-
IC SYSTEM”.
2. Remove the cover at the rear left of the machine.

30-68 PC45MR-5, PC55MR-5

30 TESTING AND ADJUSTING TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT

3. Remove cover (1).

4. Disconnect hoses (2) (pump discharged pressure side)

and (3) (LS pressure side).

5. Connect adapter C to the pump discharged pressure side,

and connect adapter D to LS pressure side.
6. Install nipples A2 to adapters C and D. Connect differential
pressure gauge E or gauge A1 of hydraulic tester A.
• When using differential pressure gauge E, connect the
high-pressure side (rear side) to the pump discharged
pressure and the low-pressure side (bottom side) to
LS pressure.
REMARK
Since the differential pressure gauge needs 12 V DC
power, connect it to 1 battery.
• When using gauge A1, measure the pressure while
replacing the same gauge since the differential pres-
sure goes up to approximately 2.9 MPa {approximate-
ly 30 kg/cm2} at maximum.
REMARK
Gauge in digital hydraulic tester B can also be used in
place of gauge A1.
7. Set all control levers and control pedals in NEUTRAL posi-
tion, and set the lock lever in OFF position.
8. Start the engine to increase the hydraulic oil temperature
to 45 to 55 °C.

PC45MR-5, PC55MR-5 30-69

TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT 30 TESTING AND ADJUSTING

9. Set each cylinder in the following state by operating the

work equipment.
• Boom cylinder: Fully extended
• Arm cylinder: Fully retracted
• Bucket cylinder: Fully retracted
10. Set the fuel control dial in MAX (High idle) position, and
measure the pump discharge pressure and LS pressure
(actuator load pressure) simultaneously when each control
lever and control pedal are in NEUTRAL position or bucket
CURL control lever is moved to full stroke position.
REMARK
Calculating LS differential pressure: LS differential pressure = Pump discharge pressure - LS pressure
For standard values, see STANDARD VALUE TABLE, “STANDARD VALUE TABLE FOR MACHINE”.
After finishing the test, remove the testing tools and restore the machine.

METHOD FOR ADJUSTING LS VALVE

If the LS differential pressure is abnormal, adjust LS valve (1)
according to the following procedure.

1. Put a matchmark on the end surfaces of adjustment screw (2) and lock nut (3).
REMARK
Put a matchmark on the end face of adjustment plug (2) and lock nut (3) to indicate the original position of
the adjustment screw (so that you can return the adjustment screw to the original position if you turn it in
the opposite direction).
2. While fixing adjustment plug (2), loosen lock nut (3).
3. Turn adjustment plug (2) and adjust differential pressure.
REMARK
If adjustment plug (2) is
• Turned clockwise, differential pressure increases.
• Turned counterclockwise, differential pressure decreas-
es.
(Reference) Adjustable range of adjustment plug (2) is as
follows:
• Counterclockwise: Within 180 °
• Clockwise: Within 180 °
4. While fixing adjustment plug (2), tighten lock nut (3).
3 Locknut (3):
27.4 to 34.3 Nm {2.8 to 3.5 kgm}
After finishing adjustment, check that LS differential pressure is normal. For details, see above described
“METHOD FOR TESTING LS DIFFERENTIAL PRESSURE”.

30-70 PC45MR-5, PC55MR-5

30 TESTING AND ADJUSTING TEST OUTLET PRESSURE OF SOLENOID VALVE

TEST OUTLET PRESSURE OF SOLENOID VALVE

Testing tools for solenoid valve outlet pressure
Symbol Part No. Part name Q'ty Remarks
- 799-101-5002 Hydraulic tester 1
1 799-101-5130 Gauge 1 Pressure range: 6 MPa
A
2 799-101-5160 Nipple 1 Size: R1/8
3 790-301-1530 Elbow 1 Size: R1/8
B 790-261-1205 Digital hydraulic tester 1 Pressure range: 70 MPa
C 799-401-3100 Adapter 1 Size: 02
D 799T-404–8500 Sensor adapter 1 Pressure range: 50 MPa

k Lower the work equipment to the ground in a stable posture, and stop the engine. Operate the con-
trol levers several times to release the remaining pressure in the piping, and then loosen the oil filler
cap of the hydraulic tank slowly to release the pressure in the tank.
Before the test, check the control circuit oil pressure is normal.
Check this item under the following conditions.
Hydraulic oil temperature: 45 to 55 °C
For testing of solenoid valve outlet pressure to perform troubleshooting or periodic maintenance, refer to this
section.

METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE BY MA-

CHINE MONITOR
1. Release the remaining pressure by referring to “RELEASE REMAINING PRESSURE FROM HYDRAULIC
SYSTEM”.
2. Open the floor. see TESTING AND ADJUSTING, “METHOD FOR OPENING AND CLOSING FLOOR”.
3. Disconnect the outlet hose (1) or (2) of the solenoid valves
to be tested.
(1): PPC lock solenoid valve
(2): 2nd travel speed selector solenoid valve

4. Connect the adapter C and connect the disconnected hose

again.

PC45MR-5, PC55MR-5 30-71

TEST OUTLET PRESSURE OF SOLENOID VALVE 30 TESTING AND ADJUSTING

5. Install the elbow A3, and the nipple C to the adapter C.

Then, connect the coupling (3) or (4) of sensor adapter D.
REMARK
• Connector (P11) side is displayed by monitoring code:
01141 “Service Press. Sens1”.
• Connector (P12) side is displayed by monitoring code:
01142 “Service Press. Sens2”.

6. Connect the connector (P04) of the sensor adapter D to

the service pressure connector (P04).
7. Start the engine.

8. Select and display (12/14) “Predefined Mon” or following

monitoring item on “SET AND OPERATE MACHINE MON-
ITOR”.
Monitoring code: 01141“ Service Press. Sens1”
Monitoring code: 01142“ Service Press. Sens2”
9. Adjust the hydraulic oil temperature within the specified
range.
10. Set the working mode to P (“Power Mode”).
11. Turn off the auto-deceleration.
12. Turn the fuel control dial to MAX (High idle) position.
Check the outlet pressure by operating each control levers and switches to turn ON or OFF the solenoid
valve.
REMARK
For the conditions for turning the solenoid valve ON/OFF, see “OPERATING CONDITION OF SOLENOID
VALVE”.
For standard values, see “STANDARD VALUE TABLE, STANDARD VALUE TABLE FOR MACHINE”.
After finishing the test, remove the testing tools and restore the machine.

METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE BY TEST-

ING TOOL
1. Release the remaining pressure. For details, see “RELEASE REMAINING PRESSURE FROM HYDRAUL-
IC SYSTEM”.
2. Tilt open the floor frame. For details, see “HOW TO OPEN AND CLOSE FLOOR”.

30-72 PC45MR-5, PC55MR-5

30 TESTING AND ADJUSTING TEST OUTLET PRESSURE OF SOLENOID VALVE

3. Disconnect outlet hose (1) or (2) of the tested solenoid

valve.
(1): PPC lock solenoid valve
(2): 2nd travel speed selector solenoid valve

4. Connect adapter C, and connect the disconnected hose

again.
5. Install elbow A3 and nipple A2 to adapter C, and connect
them to gauge A1.
REMARK
Gauge in digital hydraulic tester B can also be used in
place of gauge A1.
6. Tilt close the floor frame. For details, see “HOW TO OPEN
AND CLOSE FLOOR”.
7. Start the engine to increase the hydraulic oil temperature
to 45 to 55 °C.
8. Set the fuel control dial to MAX (High idle) position and op-
erate each control levers and switches. Measure the outlet
pressure when the solenoid valve is turned ON or OFF.
REMARK
For the conditions for turning the solenoid valve ON/OFF,
see “OPERATING CONDITION OF SOLENOID VALVE”.
For standard values, see STANDARD VALUE TABLE,
“STANDARD VALUE TABLE FOR MACHINE”.
After finishing the test, remove the testing tools and restore the machine.

OPERATING CONDITION OF SOLENOID VALVE

(1) PPC lock solenoid valve operation table
Operating
Operating condition of solenoid valve state of sole-
noid valve
OFF (De-ener-
LOCK position (Lock)
gized)
Lock lever
ON (Ener-
FREE position (Free)
gized)

(2) Operation table of 2nd travel speed selector solenoid valve

Operating
Operating condition of solenoid valve state of sole-
noid valve
OFF (Travel mode: Lo) OFF (De-ener-
gized)
Travel speed selector switch
ON (Travel mode: Hi) ON (Ener-
gized)

PC45MR-5, PC55MR-5 30-73

TEST PPC VALVE OUTLET PRESSURE 30 TESTING AND ADJUSTING

TEST PPC VALVE OUTLET PRESSURE

Tools for testing PPC valve outlet pressure
Symbol Part No. Part name Q'ty Remarks
- 799-101-5002 Hydraulic tester 1
A 1 799-101-5130 Gauge 1 Pressure range: 6 MPa
2 799-101-5160 Nipple 1 Size: R1/8
B 790-261-1205 Digital hydraulic tester 1 Pressure range: 70 MPa
C 799-401-3100 Adapter 1 Size: 02
D 799T-404–8500 Sensor adapter 1 Pressure range: 50 MPa

Before the test, check the control circuit oil pressure is normal.
Check this item under the following conditions.
Hydraulic oil temperature: 45 to 55 °C
For testing of PPC valve outlet pressure to perform troubleshooting or periodic maintenance, refer to this sec-
tion.

METHOD FOR TESTING OUTLET PRESSURE OF PPC VALVE BY MACHINE

MONITOR
Circuit diagram of PPC valve and control valve

1: Control valve 5: Boom swing PPC valve

2: Travel PPC valve 6: Blade PPC valve
3. R.H. PPC valve 7: Junction block
4. L.H. PPC valve

30-74 PC45MR-5, PC55MR-5

30 TESTING AND ADJUSTING TEST PPC VALVE OUTLET PRESSURE

PPC valve piping table

Circuit testing and operation Port names on control valve side Band color
L.H. travel (forward) PA1 Brown/Yellow
L.H. travel (reverse) PB1 Orange/Yellow
R.H. travel (forward) PA2 Black/Yellow
R.H. travel (reverse) PB2 Green/Yellow
Boom LOWER PA3 Black
Boom RAISE PB3 Yellow
Arm OUT PA4 Orange
Arm IN PB4 Green
Bucket DUMP PA5 Red
Bucket CURL PB5 Blue
Boom swing RIGHT PA6 White/Blue
Boom swing LEFT PB6 White/Red
Blade RAISE PA7 Red/Yellow
Blade LOWER PB7 Blue/Yellow
Turn LEFT PA8 White
Turn RIGHT PB8 Brown

The travel PPC valve outlet pressure can be monitored on the machine monitor.
Select and display (14/14) “Predefined Mon” or monitoring code: 07101 “Travel PPC Pressure” in “SET AND
OPERATE MACHINE MONITOR”, and perform testing.
REMARK
PPC valve outlet pressures other than the travel PPC valve
outlet pressure can be monitored by using the sensor adapter
D. For the method of using sensor adapter D, see the following
procedure.

1. Release the remaining pressure in the hydraulic cylinder circuit. See “RELEASE REMAINING PRESSURE
FROM HYDRAULIC SYSTEM”.
2. Open the floor. See “METHOD FOR OPENING AND CLOSING FLOOR”.
3. Disconnect the hoses of PPC circuit to be tested on PCC valve side or control valve side.
4. Connect the adapter C and connect the disconnected hose again.

PC45MR-5, PC55MR-5 30-75

TEST PPC VALVE OUTLET PRESSURE 30 TESTING AND ADJUSTING

5. Install the nipple A2 of hydraulic tester A, and connect the

coupling (7) or (8) of sensor adapter D.
REMARK
• Connector (P11) side is displayed by monitoring code:
01141 “Service Press. Sens1”.
• Connector (P12) side is displayed by monitoring code:
01142 “Service Press. Sens2”.

6. Connect the connector (P04) of sensor adapter D to serv-

ice pressure connector (P04).
7. Start the engine.

8. Select and display (14/14) “Predefined Mon” or following

monitoring item on “SET AND OPERATE MACHINE MON-
ITOR”.
Monitoring code: 01141“ Service Press. Sens1”
Monitoring code: 01142“ Service Press. Sens2”
9. Adjust the hydraulic oil temperature within the specified
range.
10. Set the working mode to P (“Power Mode”).
11. Turn the fuel control dial in MAX (High idle) position, and
measure the oil pressure under the following conditions.
• Each control lever and control pedal are in NEUTRAL
• Control levers and control pedals of circuit to be tested are operated to stroke end
For standard values, see “STANDARD VALUE TABLE, STANDARD VALUE TABLE FOR MACHINE”.
REMARK
The band colors identifies the installed hoses.
After finishing the test, remove the testing tools and restore the machine.

30-76 PC45MR-5, PC55MR-5

30 TESTING AND ADJUSTING TEST PPC VALVE OUTLET PRESSURE

METHOD FOR TESTING OUTLET PRESSURE OF PPC VALVE BY TESTING

TOOL
Circuit diagram of PPC valve and control valve

1: Control valve 5: Boom swing PPC valve

2: Travel PPC valve 6: Blade PPC valve
3: R.H. PPC valve 7: Junction block
4: L.H. PPC valve

PPC valve piping connection table

Circuit for testing, Operation Port name on control valve side Band color
L.H. travel (FORWARD) PA1 Brown/Yellow
L.H. travel (REVERSE) PB1 Orange/Yellow
R.H. travel (FORWARD) PA2 Black/Yellow
R.H. travel (REVERSE) PB2 Green/Yellow
Boom LOWER PA3 Black
Boom RAISE PB3 Yellow
Arm OUT PA4 Orange
Arm IN PB4 Green
Bucket DUMP PA5 Red
Bucket CURL PB5 Blue
Boom swing RIGHT PA6 White/Blue
Boom swing LEFT PB6 White/Red

PC45MR-5, PC55MR-5 30-77

TEST PPC VALVE OUTLET PRESSURE 30 TESTING AND ADJUSTING

Circuit for testing, Operation Port name on control valve side Band color
Blade RAISE PA7 Red/Yellow
Blade LOWER PB7 Blue/Yellow
Turn LEFT PA8 White
Turn RIGHT PB8 Brown

“Travel PPC Pressure” can be checked with the machine monitor.

For the machine monitor operating method, see the section of
“SET AND OPERATE MACHINE MONITOR”.

1. Release the remaining pressure. For details, see “RELEASE REMAINING PRESSURE FROM HYDRAUL-
IC SYSTEM”.
2. Tilt open the floor frame. For details, see “HOW TO OPEN AND CLOSE FLOOR”.
3. Disconnect the hose of tested PPC circuit from PPC valve or control valve.
4. Install adapter C, install nipple A2 of hydraulic tester A,
and connect gauge A1.
REMARK
Gauge in digital hydraulic tester B can also be used in
place of gauge A1.
5. Set the working mode to P (“Power Mode”) mode.
6. Start the engine to increase the hydraulic oil temperature
to 45 to 55 °C.
7. Set the fuel control dial in MAX (high idle) position, and
measure the oil pressure under the following condition.
• When each control lever and control pedal is in neutral
• When control lever and control pedal in tested circuit
are operated to stroke end
REMARK
The band colors are used to distinguish the hoses.
For standard values, see STANDARD VALUE TABLE,
“STANDARD VALUE TABLE FOR MACHINE”.

After finishing the test, remove the testing tools and restore the machine.

30-78 PC45MR-5, PC55MR-5

30 TESTING AND ADJUSTING ADJUST WORK EQUIPMENT AND SWING PPC VALVES

ADJUST WORK EQUIPMENT AND SWING PPC VALVES

If the right and left work equipment levers have large play, adjust them according to the following procedure.
For adjusting the play of work equipment PPC valve and swing PPC valve to perform troubleshooting, refer to
this section.

METHOD FOR ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC

VALVES
1. Remove the boot (1).
2. Loosen the locknut (2) and tighten it until disc (3) touches
the heads of pistons (4) (4 pieces).
REMARK
Do not move the piston when tightening.
3. Fix the position of disc (3) and tighten lock nut (2) to the
specified torque.
3 Lock nut (2):
68 to 88 Nm {7 to 9 kgm}

4. Apply gear oil and grease to the rocking portion of the

joint.
2 Rocking portion of joint:
Grease (G2-LI)
REMARK
• Apply 7 to10 mℓ of grease to all periphery (a) of the pin.
• Apply 0.2 to 0.4 mℓ of gear oil to sliding portions (b) of
joint and pin (4 places).
5. Install the boot (1).

PC45MR-5, PC55MR-5 30-79

TEST SWING PARKING BRAKE RELEASE PRESSURE 30 TESTING AND ADJUSTING

TEST SWING PARKING BRAKE RELEASE PRESSURE

Testing tools fro swing parking brake release pressure
Symbol Part No. Part name Q'ty Remarks
- 799-101-5002 Hydraulic tester 1
A 1 799-101-5130 Gauge 1 Pressure range: 6 MPa
2 799-101-5160 Nipple 1 Size: R1/8
B 790-261-1205 Digital hydraulic tester 1 Pressure range: 70 MPa
C 799-401-3100 Adapter 1 Size: 02

k Lower the work equipment to the ground, and stop the engine. Operate the control levers several
times to release the remaining pressure in the piping, and then loosen the oil filler cap of the hy-
draulic tank slowly to release the pressure in the tank.
Check this item under the following conditions.
Hydraulic oil temperature: 45 to 55 °C
For testing of swing parking brake release pressure to perform troubleshooting or periodic maintenance, refer to
this section.

METHOD FOR TESTING SWING PARKING BRAKE RELEASE PRESSURE WITH

MACHINE MONITOR
For the machine monitor operating method, see the section of “SET AND OPERATE MACHINE MONITOR”.
1. Select and display “Swing PPC Pressure” on “Monitoring
Selection Menu”. For details, see “SET AND OPERATE
MACHINE MONITOR”.
Monitoring code: 09000 “Swing PPC Pressure”
2. Start the engine to increase the hydraulic oil temperature
to 45 to 55 °C.
3. Set the fuel control dial in MAX (high idle) position, and
measure the oil pressure under the following condition.
• When the control lever is operated to swing RIGHT or
swing LEFT
• When the control lever is operated to move the arm IN
For standard values, see STANDARD VALUE TABLE, “STANDARD VALUE TABLE FOR MACHINE”.

METHOD FOR TESTING SWING PARKING BRAKE RELEASE PRESSURE BY

TESTING TOOL
1. Release the remaining pressure. For details, see RELEASE REMAINING PRESSURE FROM HYDRAULIC
SYSTEM.
2. Tilt open the floor frame. For details, see “HOW TO OPEN AND CLOSE FLOOR”.
3. Disconnect swing motor inlet hose (1).

30-80 PC45MR-5, PC55MR-5

30 TESTING AND ADJUSTING TEST SWING PARKING BRAKE RELEASE PRESSURE

4. Connect adapter C, install nipple A2, and connect gauge

A1 of hydraulic tester A.
5. Tilt close the floor frame. For details, see “HOW TO OPEN
AND CLOSE FLOOR”.
6. Start the engine to increase the hydraulic oil temperature
to 45 to 55 °C.
7. Set the fuel control dial in MAX (high idle) position, and
measure the oil pressure under the following condition.
• When the control lever is operated to swing RIGHT or
swing LEFT
• When the control lever is operated to move the arm IN
For standard values, see STANDARD VALUE TABLE,
“STANDARD VALUE TABLE FOR MACHINE”.

After finishing the test, remove the testing tools and restore the machine.

PC45MR-5, PC55MR-5 30-81

TEST AND ADJUST TRAVEL DEVIATION 30 TESTING AND ADJUSTING

TEST AND ADJUST TRAVEL DEVIATION

Check this item under the following conditions.
Hydraulic oil temperature: 45 to 55 °C
For testing and adjusting of travel deviation, refer to this section.

METHOD FOR TESTING TRAVEL DEVIATION

1. Run the engine and keep the hydraulic oil temperature to the testing condition range.
2. Fully extend the bucket cylinder, arm cylinder, and blade
cylinder, and keep the boom angle at 45 °.
3. Set the working mode to P (“Power Mode”).
4. Set the travel mode to Lo.
5. Turn the fuel control dial to MAX (High idle) position.
6. Run up 10 m with the engine speed at high idle and then
travel 20 m continuously, and measure deviation (a).
REMARK
Check that the discharged pressures of main pumps P1
and P2 are even. See “TEST AND ADJUST OIL PRES-
SURE IN WORK EQUIPMENT, TRAVEL, AND BOOM
SWING CIRCUITS”.

METHOD FOR ADJUSTING TRAVEL DEVIATION

k If the adjustment plug is loosened more than the adjustment limit, high-pressure oil may spout out.
Work with extreme care.
k Lower the work equipment to the ground, and stop the engine. Operate the control levers several
times to release the remaining pressure in the piping, and then loosen the oil filler cap of the hy-
draulic tank slowly to release the pressure in the tank.

30-82 PC45MR-5, PC55MR-5

30 TESTING AND ADJUSTING TEST AND ADJUST TRAVEL DEVIATION

REMARK
• If the machine deviates, it can be corrected by partially draining the oil discharged more from the pump
through the travel deviation adjusting plug of the main pump.
• If the travel deviation is corrected by this method, the pump discharge is reduced. As a result, the travel
speed, work equipment speed in combined operation, and relief pressure may lower.
• The following description is the method of correcting travel deviation when the machine deviates in the same
direction during both FORWARD and REVERSE travel. (If the machine deviates in different directions during
forward and reverse travel, the failure factor may not be the hydraulic pump. In this case, see “TROUBLE-
SHOOTING”, “Machine does not travel straight”.)
• Travel deviation can be corrected by this method only when the travel deviation is 200 mm or less.
1. Remove the triangular cover at the rear left of the machine.
2. Remove cover (1).

3. Check the travel deviation direction and locate the position

of travel deviation adjustment plug (2) or (3).
(2): Right deviation adjustment plug (Pressure P1 side)
(3): Left deviation adjustment plug (Pressure P2 side)
REMARK
Adjust with only the plug on one side. Do not loosen the
plug on the other side.
4. Before loosening lock nut (4), make match marks on lock
nut (4) and pump case.
5. Loosen lock nut (4) while fixing adjustment plug (2) or (3)
with a hexagonal wrench (width across flats: 4 mm).
REMARK
• Securely insert the hexagonal wrench into the adjust-
ment plug.
• If the lock nut is sealed with a vinyl seal, remove the
seal to work.
Loosening angle of lock nut (4): Approximately 90 to 180 °
6. Loosen adjustment plug (2) or (3), and adjust the travel de-
viation.
Amount of adjustment of deviation per turn of adjustment plug (2) or (3): 150 mm (Reference)
NOTICE
When adjusting, never exceed the adjustment limit (2 turns) of adjustment plug (2) or (3).

PC45MR-5, PC55MR-5 30-83

TEST AND ADJUST TRAVEL DEVIATION 30 TESTING AND ADJUSTING

REMARK
• The plug is fully tightened when shipped out of the plant. Adjust the deviation by the loosening angle of
adjustment plug (2) or (3) from the fully tightened position.
• If adjustment plug (2) or (3) is turned together with the locknut, tighten a plug fully again before starting

3 Adjustment plugs (2) and (3):

adjustment.

2.94 to 4.9 Nm {0.3 to 0.5 kgm}

• After plug (2) or (3) is tightened fully, it can be adjusted up to 2 turns in the loosening direction (counter-
clockwise).
7. Tighten lock nut (4) with adjustment plug (2) or (3) fixed.
3 Locknut (4):
11.8 to 14.7 Nm {1.2 to 1.5 kgm}
REMARK
• Width across flats of hexagonal wrench: 4 mm
• After tightening lock nut (4), seal the hole of lock nut with a vinyl seal.
8. After finishing adjustment, check the travel deviation again. For details, see “Method for testing travel devia-
tion”.

30-84 PC45MR-5, PC55MR-5

TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIP-
30 TESTING AND ADJUSTING MENT

TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT

If the cause of hydraulic drift is defective cylinder packing, lowering speed may increase during the test because
of the reasons as follows.
• Oil leaks from the bottom side to the head side when the machine is set in the measuring posture for hy-
draulic drift (where the holding pressure is applied to the bottom side). Since the volume on the head side is
less than that on the bottom side by the volume of the rod, the pressure in the head side is increased by the
oil flowing in from the bottom side.
• As pressure in the bottom side (varies depending on the leakage amount) increases, the pressure in the
head side increases and pressures are balanced on both side, and then lowering speed decreases. At this
time, operate the lever to the direction that head side oil in tested cylinder is drained to tank circuit, and
head side oil flows to drain circuit (bottom side is blocked by check valve), and pressure balance between
head side and bottom side is lost, and then lowering speed increases.
For testing of the isolating of the part causing hydraulic drift in work equipment to perform troubleshooting or
periodic maintenance, refer to this section.

METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BOOM

CYLINDER AND BUCKET CYLINDER
1. Set the work equipment in the same posture as the time
when measuring hydraulic drift, and stop the engine.
2. Apply rated load to the bucket.
Rated load
• PC45MR-5:2254 N {230 kg}
• PC55MR-5:2450 N {250 kg}
3. When testing the boom cylinder, set the boom control lever
to RAISE position. When testing the bucket cylinder, set
the bucket control lever to CURL position.
Judging method
• When the lowering speed is increased at this time: The cylinder packing is defective.
• No change: The control valve is defective.
REMARK
If the accumulator pressure is reduced, run the engine for approximately 5 seconds to accumulate the pres-
sure.

METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF ARM

CYLINDER
1. Move the arm cylinder, stop it at approximately 100 mm
before IN stroke end, and stop the engine.
2. Turn the starting switch to ON position.
3. Operate the arm control lever to IN to test.
Identifying causes
• When the lowering speed is increased at this time:
The cylinder packing is defective.
• When no change occurs: The control valve is defec-
tive.
REMARK
If the accumulator pressure decreases, run the engine for
approximately 10 seconds to accumulate the pressure.

PC45MR-5, PC55MR-5 30-85

TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIP-
MENT 30 TESTING AND ADJUSTING

METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF PPC

VALVE
Measure the hydraulic drift of the work equipment when the lock lever is in LOCK and FREE positions with the
accumulator charged fully.
In case there is a difference of hydraulic drift between LOCK and FREE positions, the PPC valve is defective
(internal defect).
NOTICE
Operate the lock lever when the starting switch is turned to ON position.
REMARK
If the accumulator pressure decreases, run the engine for approximately 10 seconds to accumulate the pres-
sure.

30-86 PC45MR-5, PC55MR-5

30 TESTING AND ADJUSTING TEST OIL LEAKAGE

TEST OIL LEAKAGE

Tools for testing oil leakage
Symbol Part No. Part name Q'ty Remarks
A Commercially
Measuring cylinder 1
available
B 07376-70422 Plug 1 Size: 04
C Commercially
Block 1
available

Check this item under the following conditions.

Hydraulic oil temperature: 45 to 55 °C
For testing of oil leakage to perform troubleshooting or periodic maintenance, refer to this section.

METHOD FOR TESTING OIL LEAKAGE FROM BOOM CYLINDER

1. Set the boom cylinder at RAISE stroke end, and stop the engine.
2. Release the remaining pressure from the piping on the boom cylinder head side. For details, see “RE-
LEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM”.
REMARK
Operate the lever in the boom RAISE direction only to release the remaining pressure.
3. Disconnect hose (1) on the cylinder head side, and block
the hose side by using plug B.
k Be careful not to disconnect the hose on the cylin-
der bottom side.
4. Start the engine, and perform boom RAISE relief with the
fuel control dial at MAX (High idle) position.
k Be careful not to operate the lever to “Boom LOW-
ER” side.
5. 30 seconds after relief starts, measure the leakage from
the cylinder head side for 1 minute by using measuring cyl-
inder A.
For standard values, see STANDARD VALUE TABLE, “STANDARD VALUE TABLE FOR MACHINE”.
After finishing the test, remove the testing tools and restore the machine.

METHOD FOR TESTING OIL LEAKAGE FROM ARM CYLINDER

1. Set the arm cylinder at IN stroke end, and stop the engine.
2. Release the remaining pressure from the piping on the arm cylinder head side. For details, see “RELEASE
REMAINING PRESSURE FROM HYDRAULIC SYSTEM”.
REMARK
Operate the lever in the arm IN direction only to release the remaining pressure.
3. Disconnect hose (2) on the cylinder head side and block
the hose side by using plug B.
k Be careful not to disconnect the hose on the cylin-
der bottom side.
4. Start the engine, and perform arm IN relief with the fuel
control dial at MAX (High idle) position.
k Be careful not to operate the lever to “Arm OUT”
side.

PC45MR-5, PC55MR-5 30-87

TEST OIL LEAKAGE 30 TESTING AND ADJUSTING

5. 30 seconds after relief starts, measure the leakage from the cylinder head side for 1 minute by using meas-
uring cylinder A.
For standard values, see STANDARD VALUE TABLE, “STANDARD VALUE TABLE FOR MACHINE”.
After finishing the test, restore the machine.

METHOD FOR TESTING OIL LEAKAGE FROM BUCKET CYLINDER

1. Set the bucket cylinder at CURL stroke end, and stop the engine.
2. Release the remaining pressure from the piping on the bucket cylinder head side. For details, see “RE-
LEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM”.
REMARK
Operate the lever in the bucket CURL direction only to release the remaining pressure.
3. Disconnect hose (3) on the cylinder head side and block
the hose side by using plug B.
k Be careful not to disconnect the hose on the cylin-
der bottom side.
4. Start the engine, and perform bucket CURL relief with the
fuel control dial at MAX (High idle) position.
k Be careful not to operate the lever to “Bucket
DUMP” side.
5. 30 seconds after relief starts, measure the leakage from
the cylinder head side for 1 minute by using measuring cyl-
inder A.
For standard values, see STANDARD VALUE TABLE, “STANDARD VALUE TABLE FOR MACHINE”.
After finishing the test, restore the machine.

METHOD FOR TESTING OIL LEAKAGE FROM BLADE CYLINDER

1. Start engine and drive the machine so that the idler sides of tracks get onto the wooden blocks, etc. to raise
the front side of machine.
k Raise the front side of machine until blade does not touch the ground even when the blade lift
cylinder is extended to its LOWER stroke end.
k Set work equipment lock lever to LOCK position and put blocks C, etc. as chocks under the rear
of tracks.
2. Fully extend the blade cylinder to its LOWER stroke end and stop the engine.
3. Release the remaining pressure from the piping on the blade cylinder head side. For details, see “RE-
LEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM”.
REMARK
Bleed air only by lowering the blade.
4. Disconnect hose (4) on the cylinder head side and block
the hose side by using plug B.
k Be careful not to disconnect the hose on the cylin-
der bottom side.
5. Start the engine, and perform blade LOWER relief with the
fuel control dial at MAX (High idle) position.
k Be careful not to operate the lever to “Blade
RAISE” side.
6. 30 seconds after relief starts, measure the leakage from
the cylinder head side for 1 minute by using measuring cyl-
inder A.
For standard values, see STANDARD VALUE TABLE, “STANDARD VALUE TABLE FOR MACHINE”.

30-88 PC45MR-5, PC55MR-5

30 TESTING AND ADJUSTING TEST OIL LEAKAGE

After finishing the test, restore the machine.

PC45MR-5, PC55MR-5 30-89

BLEED AIR FROM HYDRAULIC CIRCUIT 30 TESTING AND ADJUSTING

BLEED AIR FROM HYDRAULIC CIRCUIT

Tools for bleeding air from hydraulic circuit
Symbol Part No. Part name Q'ty Remarks
Commercially
A Oil container 1
available
Commercially
B Air bleeding hose 1
available

k Place the machine on a level ground, lower the work equipment completely to the ground in a stable
posture, set the lock lever to LOCK position, and then stop the engine.
k Immediately after the engine is stopped, its parts and oil are still very hot and may cause burn injury.
Wait for the temperature to go down, and then start the work.
For releasing the air from hydraulic systems to perform troubleshooting, refer to this section.
●: Execution of work
→: Go to next procedure
Air bleeding procedure and items
1 2 3 4 5 6 7
PRES-
Details of work Bleeding Bleeding Check of
Bleeding Bleed air SURIZE
Start the air from air from oil level
air from from cylin- HY-
engine. swing mo- travel mo- and opera-
main pump der DRAULIC
tor tor tion
TANK
• Hydraulic oil change ● ●
● ● ● ● ●
• Strainer cleaning (*1) (*1)
• Replacement of re-
● → → → ● ●
turn filter element
• Replacement and re-
pair of main pump
● ● ● → → ● ●
• Removal of suction
piping
• Replacement and re-
pair of control valve
● ● → → ● ●
• Removal of control
valve piping
• Replacement and re-
pair of cylinder
● ● → → ● ●
• Removal of cylinder
piping
• Replacement and re-
pair of swing motor
● → ● → ● ●
• Removal of swing
motor piping
• Replacement and re-
pair of travel motor
● → → ● ● ●
• Removal of travel
motor piping

*1: Bleed air from the swing motor and travel motor only when the oil in the motor case is drained.

30-90 PC45MR-5, PC55MR-5

30 TESTING AND ADJUSTING BLEED AIR FROM HYDRAULIC CIRCUIT

METHOD FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT

Method for bleeding air from main pump
NOTICE
• If the pump is operated without filling the pump case with hydraulic oil, abnormal heat will be gener-
ated and this may cause a premature damage to the pump. Accordingly, bleed air securely.
REMARK
• Perform it when any hydraulic component or oil is replaced.
• Keep the oil filler cap of the hydraulic tank loosened during air bleeding work of the main pump.
1. Remove the triangular cover at the rear left of the machine.
2. Remove cover (1).

3. Loosen air bleeder (2) of the main pump, install vinyl hose
B, and put its end in oil container A.
4. Add oil to the hydraulic tank, and start the engine with fuel
control dial set in MIN position (Low idle).
5. When oil without air starts to flow out, tighten air bleeder
(2).
3 Air bleeder (2):
8.8±1 Nm {0.9±0.1 kgm}
6. Pressurize the hydraulic tank. For details, see “PRESSUR-
IZE HYDRAULIC TANK”.
When starting the engine after bleeding air from main pump, run the engine for 10 minutes with the fuel control
dial at MIN (Low idle) position.

Method for bleeding air from cylinder

1. Start and run the engine for approximately 5 minutes with the fuel control dial at MIN (Low idle) position.
2. Open oil cap of the hydraulic tank.
3. Repeat raising and lowering the boom 4 to 5 times while running the engine with the fuel control dial at MIN
(Low idle) position.
REMARK
Stop the piston rod at approximately 100 to 200 mm before each stroke end to avoid relieving.
4. Repeat raising and lowering the boom 4 to 5 times while running the engine with the fuel control dial at
MAX (High idle) position.
REMARK
Stop the piston rod at approximately 100 to 200 mm before each stroke end to avoid relieving.
5. Move the piston rod to the stroke end to relieve the circuit while running the engine with the fuel control dial
at MIN (Low idle) position.
6. Bleed air from the arm cylinder, bucket cylinder, blade cylinder and boom swing cylinder according to step 2
to 4.

PC45MR-5, PC55MR-5 30-91

BLEED AIR FROM HYDRAULIC CIRCUIT 30 TESTING AND ADJUSTING

Method for bleeding air from swing motor

NOTICE
If the air is not bled from the swing motor and the machine is operated, the swing motor bearings may
be damaged.
REMARK
Perform this only when the oil inside the swing motor case is drained.
1. Start the engine and run it with the fuel control dial at MIN (Low idle) position.
2. Open oil cap of the hydraulic tank.
3. With the fuel control dial at MIN (Low idle) position, swing to the right and left 3 times.

Method for bleeding air from travel motor

1. Start the engine, and set the fuel control dial to MIN (Low idle) position.
2. Open oil cap of the hydraulic tank.
3. Raise L.H. track off the ground by using the work equipment.
4. With the fuel control dial at MIN (Low idle) position, run L.H. track idle for approximately 30 seconds.
REMARK
Work on R.H. track in the same way.

Method for checking oil level

1. Start the engine, retract the arm cylinder and bucket cylin-
der fully, lower the work equipment to the ground, and stop
the engine.

2. Check the oil level by sight gauge (4) at the rear of the hy-
draulic tank.
REMARK
• If the hydraulic oil level is between “H” and “L”, it is nor-
mal.
• If the oil level is insufficient, add oil.

30-92 PC45MR-5, PC55MR-5

30 TESTING AND ADJUSTING PRESSURIZE HYDRAULIC TANK

PRESSURIZE HYDRAULIC TANK

k Immediately after the engine is stopped, its parts and oil are still very hot and may cause burn injury.
Wait for the temperature to go down, and then start the work.
k When removing the oil filler cap, the oil may spout out. Turn it slowly to release the internal pres-
sure, then remove it.
k When the hydraulic tank oil filler cap was removed, be sure to pressurize the hydraulic tank.
NOTICE
The pump may suction the air if the pressurization is not performed for the hydraulic tank, and it may
have harmful effect to the devices.
When the hydraulic tank needs to be pressurized to perform troubleshooting, refer to this section.

METHOD FOR PRESSURIZING HYDRAULIC TANK

1. Open the oil filler cap.
2. Start the engine, and set the fuel control dial to MIN (Low idle) position.
3. Set the lock lever to FREE position.
4. Operate the cylinder rod of boom, bucket, arm and boom
swing to the stroke end.
NOTICE
When operating each control lever, do not relieve the
cylinder.
5. Set the lock lever to LOCK position and stop the engine.
6. Tighten the oil filler cap securely.
By doing so, the hydraulic tank is pressurized.

After finishing the work, restore the machine.

PC45MR-5, PC55MR-5 30-93

METHOD FOR OPENING AND CLOSING FLOOR UNIT 30 TESTING AND ADJUSTING

CAB AND ITS ATTACHMENTS

METHOD FOR OPENING AND CLOSING FLOOR UNIT
k When opening and closing the floor, observe the follow-
ing warning and precautions for the work.
k Wrong operation may cause serious personal injury or
death.
k Do not open or close the floor when the machine is on
a slope.
k Do not open and close the floor in strong winds.
k Immediately after the engine is stopped, its parts and
oil are still very hot and may cause burn injury. Check
that the temperature inside of engine compartment has
been dropped before performing the opening or closing
of floor.
k Do not stand on the floor or enter into the cab while
floor is open.
k While opening or closing the floor, do not enter under
the floor.
k Do not start the engine while floor is open.
k If any damage or problem is found at the floor opening
lock part, stop the work, close the floor, and then ask
your Komatsu distributor for repair.
k Do not remove the floor mounting bolts (A).
The floor may jump up unexpectedly and it is danger-
ous.
Set the machine to the following conditions before opening the floor.
1. Set the machine in the posture shown in the figure.
1) Start the engine, and run it at low speed.

2) Set the lock lever to FREE position (F).

Be sure to operate the lock lever by the operating por-
tion on the top.
3) Push the blade control lever forward to lower the
blade to the ground.
4) Operate the work equipment control levers to extend
bucket cylinder and arm cylinder to their stroke end,
and then lower the boom gently.
Lower the bucket link to the ground.

30-94 PC45MR-5, PC55MR-5

30 TESTING AND ADJUSTING METHOD FOR OPENING AND CLOSING FLOOR UNIT

5) Set the lock lever to LOCK position (L).

Be sure to operate the lock lever by the operating por-
tion on the top.

2. Put the wooden blocks on the front and rear sides of the
tracks so that the machine does not move.

9 J A0 5 4 6 6

METHOD FOR OPENING FLOOR UNIT

METHOD FOR OPENING FLOOR UNIT: CANOPY SPEC
1. Remove the triangle cover fixing bolts (1) (M10, 3 pieces),
and remove the triangle cover (2).

2. Remove the cover fixing bolts (3) (M8, 4 pieces), and re-
move the cover (4).

PC45MR-5, PC55MR-5 30-95

METHOD FOR OPENING AND CLOSING FLOOR UNIT 30 TESTING AND ADJUSTING

3. Remove the floor tilt fixing bolts (5) (M14, 2 pieces).

4. Pull the engine rear cover (6) backward to open it.

Open the engine rear cover (6) fully and it is secured by
rod (7).

5. Remove the floor tilt fixing bolt (8) (M14, 1 piece).

6. Close the engine rear cover (6).

7. Open the inspection window (9).

30-96 PC45MR-5, PC55MR-5

30 TESTING AND ADJUSTING METHOD FOR OPENING AND CLOSING FLOOR UNIT

8. While pulling the floor lock release lever (10) to FREE po-
sition (F) with your left hand, hold the handle (11) with your
right hand and push it up to the direction of arrow (approxi-
mately 45 °) to release the floor lock.
9. Hold the handle (11) and push it up to the direction of ar-
row (approximately 45 °) to raise the floor.
REMARK
• If the floor does not rise, the release lever is not in RE-
LEASE position.
Pull back the handle with your right hand, and repeat
the preceding procedure again.
• Since the gas spring assists the opening of floor, the
force to push up the floor decreases in the following
cases. Take care.
• When the outside air temperature is low
• When the force of gas spring decreases due to the
long-term operation

10. Once the floor rises, push it up until the lock pin (12)
reaches to the locking notch (14) of lock plate (13).
When the lock pin (12) moves into the locking notch (14),
the first lock is fixed.

11. Insert the second lock pin (15) into the locking hole (16)
securely from inside.
12. Turn the lock pin (15) until its upper part (hook to prevent
from coming off) catches the pin (17) of inserting part se-
curely.
NOTICE
Check that the lock pin securely catches the pin and
the pin does not come off.

The second lock is fixed, and the floor opening work is completed.

PC45MR-5, PC55MR-5 30-97

METHOD FOR OPENING AND CLOSING FLOOR UNIT 30 TESTING AND ADJUSTING

METHOD FOR OPENING FLOOR UNIT: CAB SPEC

1. Remove the triangle cover fixing bolts (1) (M10, 3 pieces),
and remove the triangle cover (2).

2. Remove the floor tilt fixing bolts (3) (M14, 2 pieces).

3. Pull the engine rear cover (4) backward to open it.

Open the engine rear cover (4) fully and it is secured by
rod (5).

4. Remove the floor tilt fixing bolts (6) (M14, 4 pieces).

5. Close the engine rear cover (4).

6. Open the inspection window (7).

30-98 PC45MR-5, PC55MR-5

30 TESTING AND ADJUSTING METHOD FOR OPENING AND CLOSING FLOOR UNIT

7. While pulling the floor lock release lever (8) to FREE posi-
tion (F) with your left hand, hold the handle (9) with your
right hand and push it up to the direction of arrow (approxi-
mately 45 °) to release the floor lock.
8. Hold the handle (9) and push it up to the direction of arrow
(approximately 45 °) to raise the floor.
REMARK
• If the floor does not rise, the release lever is not in RE-
LEASE position.
Pull back the handle with your right hand, and repeat
the preceding procedure again.
• Since the gas spring assists the opening of floor, the
force to push up the floor decreases in the following
cases. Take care.
• When outside air temperature is low
• When the force of gas spring decreases due to the
long-term operation

9. Once the floor rises, push it up until the lock pin (10)
reaches to the locking notch (12) of lock plate (11).
When the lock pin (10) moves into the locking notch (12),
the first lock is fixed.

10. Insert the second lock pin (13) into the locking hole (14)
securely from inside.
11. Turn the lock pin (13) until its upper part (hook to prevent
from coming off) catches the pin (15) of inserting part se-
curely.
NOTICE
Check that the lock pin securely catches the pin and
does not come off.

The second lock is fixed, and the floor opening work is completed.

PC45MR-5, PC55MR-5 30-99

METHOD FOR OPENING AND CLOSING FLOOR UNIT 30 TESTING AND ADJUSTING

METHOD FOR CLOSING FLOOR UNIT

NOTICE
Before closing the floor, check the wiring harness, piping, and seat inside floor and in the revolving
frame for damage or problem.
If any damage or problem is found, ask your Komatsu distributor for repair.

METHOD FOR CLOSING FLOOR UNIT: CANOPY SPEC

1. Remove the lock pin (15) of second lock, and insert it into
holder hole (18).
If it is hard to remove the lock pin (15), hold the handle (11)
and while pulling it up, remove the lock pin (15).

2. While pulling the floor lock release lever (10) to FREE po-
sition (F) with your left hand, hold the handle (11) with your
right hand and push it down slowly to the direction of arrow
(approximately 45 °) to release the first lock.
3. Hold the handle (11) with your right hand and lower the
floor slowly to the direction of arrow (approximately 45 °).
NOTICE
Check that there is no pinched or damaged wiring har-
ness and piping.

4. Close the inspection window (9).

30-100 PC45MR-5, PC55MR-5

30 TESTING AND ADJUSTING METHOD FOR OPENING AND CLOSING FLOOR UNIT

5. Open the engine rear cover (6).

Open the engine rear cover (6) toward you fully and it is
secured by the rod (7).

6. Tighten the floor tilt fixing bolt (8) (M14, 1 piece).

3 Tightening torque:
156.8 to 196.0 Nm {16.0 to 20.0 kgm, 116 to
145 lbft}
REMARK
If any of the floor tilt fixing bolts is damaged, replace it with
a Komatsu genuine part of the same size.
7. Close the engine rear cover (6).

8. Tighten the floor tilt fixing bolts (5) (M14, 2 pieces).

3 Tightening torque:
156.8 to 196.0 Nm {16.0 to 20.0 kgm, 116 to
145 lbft}
REMARK
If any of the floor tilt fixing bolts is damaged, replace it with
a Komatsu genuine part of the same size.

9. Install the cover (4) with the cover fixing bolts (3) (M8, 4
pieces).

10. Install the triangle cover (2) with the triangle cover fixing
bolts (1) (M10, 3 pieces).

Floor closing work is completed.

PC45MR-5, PC55MR-5 30-101

METHOD FOR OPENING AND CLOSING FLOOR UNIT 30 TESTING AND ADJUSTING

METHOD FOR CLOSING FLOOR UNIT: CAB SPEC

1. Remove the lock pin (13) of the second lock, and insert it
into holder hole (16).
If it is hard to remove the lock pin (13), hold the handle (9)
and while pulling it up, remove the lock pin (13).

2. While pulling the floor lock release lever (8) to FREE posi-
tion (F) with your left hand, hold the handle (9) with your
right hand and push it down slowly to the direction of arrow
(approximately 45 °) to release the first lock.
3. Hold the handle (9) with your right hand and lower the floor
slowly to the direction of arrow (approximately 45 °).
NOTICE
Check that there is no pinched or damaged wiring har-
ness and piping.

4. Close the inspection window (7).

5. Open the engine rear cover (4).

Open the engine rear cover (4) toward you fully and it is
secured by the rod (5).

30-102 PC45MR-5, PC55MR-5

30 TESTING AND ADJUSTING METHOD FOR OPENING AND CLOSING FLOOR UNIT

6. Tighten the floor tilt fixing bolts (6) (M14, 4 pieces).

8. Tighten the floor tilt fixing bolts (3) (M14, 2 pieces).

3 Tightening torque:
156.8 to 196.0 Nm {16.0 to 20.0 kgm, 116 to
145 lbft}
REMARK
If any of the floor tilt fixing bolts is damaged, replace it with
a Komatsu genuine part of the same size.

9. Install the triangle cover (2) with the triangle cover fixing
bolts (1) (M10, 3 pieces).

Floor closing work is completed.

PC45MR-5, PC55MR-5 30-103

SET AND OPERATE MACHINE MONITOR 30 TESTING AND ADJUSTING

ELECTRICAL SYSTEM
SET AND OPERATE MACHINE MONITOR

Machine monitor (Monitor panel section)

(a): Multi-information display
Depending on ambient temperature and condition of battery, battery voltage may drop suddenly and machine
monitor display disappears when engine is started. But this phenomenon does not mean that machine monitor
is defective.
Machine monitor (Switch section)
1: Function switches
F1: F1 Function switch
F2: F2 Function switch
F3: F3 Function switch
F4: F4 Function switch
F5: F5 Function switch
F6: F6 Function switch
F7: F7 Function switch
F8: F8 Function switch
The function of each function switch is indicated by the icon which is displayed just above function switches F1
to F4 or on the left side of F5 to F8 on the multi-information display panel (a).
If the icon for a function switch is not displayed, that function switch is not working.

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30 TESTING AND ADJUSTING SET AND OPERATE MACHINE MONITOR

Operator mode and service mode of machine monitor

Machine monitor has operator mode and service mode. Various information is displayed on multi-information
display (a).
Some items are displayed automatically according to the configuration of the machine monitor whereas the oth-
er items can be displayed only when the machine monitor is operated with switches.
• Operator mode
The information items in this mode are ordinarily displayed. The operator can display and set them by the
operation with switches. (Display and setting of some items need special operation of switches.)
For details, see Operation and Maintenance Manual.

Operator mode
DISPLAY OF PASSWORD INPUT
MAINTENANCE TIME CAUTION LAMP
BASIC OPERATION OF MACHINE MONITOR WHEN STARTING ENGINE IN NORMAL SITUATION
BASIC OPERATION OF MACHINE MONITOR WHEN ENGINE IS STOPPED IN NORMAL SITUATION
BASIC OPERATION OF MACHINE MONITOR WHEN ENGINE IS STARTED WHILE ENGINE SHUTDOWN SEC-
ONDARY SWITCH IS ON
AUTO-DECELERATION FUNCTION
HOW TO USE WORKING MODE SELECTING FUNCTION
TRAVEL SPEED SELECTOR SWITCH
BUZZER CANCEL FUNCTION
SERVICE METER / CLOCK
MAINTENANCE SCREEN SETTING
USER MENU
BASIC OPERATION OF MACHINE MONITOR WHEN TROUBLE OCCURS WHILE OPERATING MACHINE
AFTERTREATMENT DEVICES REGENERATION
ACTION LEVEL DISPLAY
Following functions become operational by performing special operations.
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY)
CHECKING FUNCTION OF SERVICE METER
METHOD FOR SETTING USAGE LIMITATION AND CHANGING PASSWORD

• Service Mode
The information items in this mode are not ordinarily displayed. Technicians can change display and set-
tings by operating the switches specially. This mode is used for testing, adjusting, or troubleshooting.
Service Mode
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION
METHOD FOR CONFIRMING ABNORMALITY RECORD (MECHANICAL SYSTEMS)
METHOD FOR CONFIRMING ABNORMALITY RECORD (ELECTRICAL SYSTEMS)
METHOD FOR CONFIRMING MAINTENANCE RECORD
METHOD FOR OPERATING MAINTENANCE MODE SETTING
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING

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SET AND OPERATE MACHINE MONITOR 30 TESTING AND ADJUSTING

Service Mode
METHOD FOR SETTING WITH DEFAULT SETTING MENU (KEY-ON MODE)
METHOD FOR SETTING WITH DEFAULT SETTING MENU (UNIT)
METHOD FOR SETTING WITH DEFAULT SETTING MENU (WITH/WITHOUT ATTACHMENT)
METHOD FOR SETTING WITH DEFAULT SETTING MENU (AUTO IDLE STOP TIMER FIXING)
METHOD FOR OPERATING TESTING MENU (CYLINDER CUT-OUT OPERATION)
METHOD FOR OPERATING TESTING MENU (REGENERATION FOR SERVICE)
METHOD FOR OPERATING TESTING MENU (KDPF MEMORY RESET)
METHOD FOR OPERATING TESTING MENU (RAIL PRESSURE MEMORY RESET)
METHOD FOR ADJUSTING WITH ADJUSTING MENU (PUMP ABSORPTION TORQUE)
METHOD FOR ADJUSTING WITH ADJUSTING MENU (ATTACHMENT EPC 2 ADJUSTMENT)
METHOD FOR ADJUSTING WITH ADJUSTING MENU (ATTACHMENT EPC 3 ADJUSTMENT)
METHOD FOR OPERATING BATTERY DISCONNECT SWITCH SETTING
METHOD FOR CONFIRMING KOMTRAX SETTINGS (TERMINAL STATUS)
METHOD FOR CONFIRMING KOMTRAX SETTINGS (GPS AND COMMUNICATION STATUS)
METHOD FOR CONFIRMING KOMTRAX SETTINGS (MODEM STATUS)
METHOD FOR DISPLAYING SERVICE MESSAGE

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30 TESTING AND ADJUSTING SET AND OPERATE MACHINE MONITOR

OPERATOR MODE
The following are items which needs specific switch operation in operator mode.
For details of contents and operations of each function and display, see STRUCTURE AND FUNCTION, “MA-
CHINE MONITOR”or the “OPERATION AND MAINTENANCE MANUAL”.

CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY)

If the following operation is performed with the function
switches while the standard screen is displayed, LCD screen
turns completely white.
Switch operations (While pressing F8): F8 + F6
• When finishing the operation of the switches, release F6
first.
• If there is a display error in the LCD, only that part is indi-
cated in black.
• An LCD panel sometimes shows black spots (spots that
remain unlit) and bright spots (spots that remain lit) as one
of the characteristics.
If the number of the bright points and black points does not exceed 10, the LCD panel is not faulty or defec-
tive.
• To return to the former screen, press any one of the function switches.

CHECKING FUNCTION OF SERVICE METER

When checking the service meter with the starting switch in
OFF position, operate the function switches as follows to dis-
play only the service meter.
Switch operations (While pressing F2): F2 + F3
REMARK
• There is some time lag in start of the LCD, so hold down
the switches until the service meter is displayed.
• If you release one of the switches, the monitor goes off.

METHOD FOR SETTING USAGE LIMITATION AND CHANGING PASSWORD

On the machine monitor, a password can be set as a user limitation setting. If the password has been set, a
password enter screen is displayed for resetting of maintenance items.
Perform the Usage Limitation Setting and Change Password functions according to the following procedure.
1. While displaying the standard screen, operate the function
switches as follows.
Switch operation (While pressing F8, press other switches
in order): F8 + F5 → F5 → F5
REMARK
This operation of the switches is not accepted until 10 mi-
nutes elapsed after the starting switch is turned to ON po-
sition.

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SET AND OPERATE MACHINE MONITOR 30 TESTING AND ADJUSTING

2. When “Usage Limitation Password” screen is displayed,

input the current password with the function switches.
F1: Decreases the number by 1
F2: Increases the number by 1
F3: Returns the screen to standard screen
F4: Enters the input password
F6: Moves the input position leftward
F7: Moves the input position rightward
F8: Clears all the input digits
REMARK
• Default password: 000000
• When the inputted password is correct, the screen changes to the next screen.
• When the inputted password is incorrect, a message to request inputting the password again is dis-
played.
• The password for usage limitation and the engine start lock password are not identical.
3. On “Usage Limitation Setting” screen, select a setting with
the function switch.
F1: Moves the selection down by one item
F2: Moves the selection up by one item
F3: Cancels the selection and returns to the previous
screen
F4: Enters the selection

4. On “Usage Limitation ON/OFF” screen, select a setting

with the function switch.
“OFF”: The password input screen is not displayed
“ON”: The password input screen appears for the setting of
the breaker and attachment, or the reset operation of
maintenance items.
F1: Moves the selection down by one item
F2: Moves the selection up by one item
F3: Cancels the selection and returns to the previous
screen
F4: Enters the selection
5. Display “Usage Limitation Setting” and select “Change
Password”.
F1: Moves the selection down by one item
F2: Moves the selection up by one item
F3: Cancels the selection and returns to the previous
screen
F4: Enters the selection

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30 TESTING AND ADJUSTING SET AND OPERATE MACHINE MONITOR

6. When “Usage Limitation New Password Input” screen is

displayed, input new password with the function switches.
F1: Decreases the number by 1
F2: Increases the number by 1
F3: Returns to “Usage Limitation Setting” menu
F4: Enters new password
F6: Moves the input position leftward
F7: Moves the input position rightward
F8: Clears all the input digits
REMARK
• Default password: 000000
• When the inputted password is correct, the screen changes to the next screen.
• When the inputted password is incorrect, a message to request inputting the password again is dis-
played.
• Set a new password of 4 to 6 digits (If it has only 3 or less digits or has 7 or more digits, it is not accept-
ed).
7. When “Usage Limitation New Password Input” screen is
displayed again, input a new password again with the
function switches.
F1: Decreases the number by 1
F2: Increases the number by 1
F3: Returns to “Usage Limitation Setting” menu
F4: Enters new password
F6: Moves the input position leftward
F7: Moves the input position rightward
F8: Clears all the input digits
REMARK
If the password is different from the previous one, the monitor displays a message prompting reinput of the
password.
If the standard screen is displayed after the screen to noti-
fy completion of setting is displayed, the password is
changed successfully.

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SET AND OPERATE MACHINE MONITOR 30 TESTING AND ADJUSTING

SERVICE MODE
METHOD FOR OPERATING SERVICE MODE
To change the mode of the machine monitor to the service mode from the operator mode, perform the following
operation.
This operation is always required when you use the service mode.
1. While displaying the standard screen, press the function
switch F8 to select following switches (F8 + F1 → F2 →
F3).
REMARK
Switch operations which use SERVICE MODE are accept-
ed only while the standard screen is displayed.

2. When “Service Menu” screen is displayed, the service

mode is selected. Select a service menu you use.
F1: Moves the selection down by one item
F2: Moves the selection up by one item
F3: Returns the screen to the “standard” screen (operator
mode)
F4: Enters the selection
F8: Changes the screen to Code Input screen.

REMARK
• If you press the function switch and input the code on
Input Code screen, the menu is selected directly.
F1: Decreases the number by 1
F2: Increases the number by 1
F3: Cancels the input and returns the screen to “Serv-
ice Menu” screen
F4: Enters the input code
F6: Moves the input position leftward
F7: Moves the input position rightward
• Items with 2-digit codes are the menus displayed on “Service Menu” screen. The items on the right are
the menus on the next hierarchy.
The following shows the items selectable with “Service Menu” (including some items which need special
switching operations).

The menu items which can be selected in Service Menu

Code Item Reference page
METHOD FOR CHECKING PRE-DEFINED MONITORING
01 Pre-defined Monitoring
INFORMATION
METHOD FOR CHECKING SELF-DEFINE MONITORING
02 Self-define Monitoring
INFORMATION

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30 TESTING AND ADJUSTING SET AND OPERATE MACHINE MONITOR

Code Item Reference page

Mechanical Sys Abnormali- METHOD FOR CONFIRMING ABNORMALITY RECORD
Abnormality ty Record (MECHANICAL SYSTEMS)
03
Record Electrical Sys Abnormality METHOD FOR CONFIRMING ABNORMALITY RECORD
Record (ELECTRICAL SYSTEMS)
04 Maintenance Record METHOD FOR CONFIRMING MAINTENANCE RECORD
METHOD FOR OPERATING MAINTENANCE MODE SET-
05 Maintenance Mode Setting
TING
METHOD FOR OPERATING PHONE NUMBER ENTRY
06 Phone Number Entry
SETTING
METHOD FOR SETTING WITH DEFAULT SETTING MENU
Key-on mode
(KEY-ON MODE)
METHOD FOR SETTING WITH DEFAULT SETTING MENU
Unit
(UNIT)
07 Default
METHOD FOR SETTING WITH DEFAULT SETTING MENU
With/Without Attachment
(WITH/WITHOUT ATTACHMENT)
Auto Idle Stop Timer Set- METHOD FOR SETTING WITH DEFAULT SETTING MENU
ting (AUTO IDLE STOP TIMER FIXING)
Cylinder Cutout Mode Op- METHOD FOR OPERATING TESTING MENU (CYLINDER
eration CUT-OUT OPERATION)
Active Regeneration for METHOD FOR OPERATING TESTING MENU (REGENER-
Diagnostic Service ATION FOR SERVICE)
08
Tests METHOD FOR OPERATING TESTING MENU (KDPF MEM-
KDPF Memory Reset
ORY RESET)
Rail Pressure Memory Re- METHOD FOR OPERATING TESTING MENU (RAIL PRES-
set SURE MEMORY RESET)
METHOD FOR ADJUSTING WITH ADJUSTING MENU
Pump Absorption Torque
(PUMP ABSORPTION TORQUE)
Attachment EPC 2 Adjust- METHOD FOR ADJUSTING WITH ADJUSTING MENU (AT-
09 Adjustment
ment TACHMENT EPC 2 ADJUSTMENT)
Attachment EPC 3 Adjust- METHOD FOR ADJUSTING WITH ADJUSTING MENU (AT-
ment TACHMENT EPC 3 ADJUSTMENT)
METHOD FOR OPERATING BATTERY DISCONNECT
10 Batt. Disconnect Set
SWITCH SETTING
METHOD FOR CONFIRMING KOMTRAX SETTINGS (TER-
Terminal Status
MINAL STATUS)
KOMTRAX GPS & Communication METHOD FOR CONFIRMING KOMTRAX SETTINGS (GPS
11
Settings State AND COMMUNICATION STATUS)
METHOD FOR CONFIRMING KOMTRAX SETTINGS (MO-
Modem Information
DEM STATUS)
12 Service Message METHOD FOR DISPLAYING SERVICE MESSAGE

METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION

The machine monitor can monitor the condition of the machine in real time by receiving signals from various
switches, sensors, and actuators installed to various parts of the machine and the information from the control-
lers which is controlling them.
In Pre-define Monitoring, frequently used monitoring items are already selected beforehand.

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SET AND OPERATE MACHINE MONITOR 30 TESTING AND ADJUSTING

1. Select “Pre-defined Mon” on “Service Menu” screen.

2. On “Pre-defined Mon” screen, displayed items can be

checked with the function switch.
F1: Selects Display of Non-display of auto-deceleration pi-
lot lamp
F2: Selects HOLD or releasing HOLD (If HOLD is selected,
HOLD part is hatched)
F3: Returns the screen to “Service Menu” screen
F5: Changes the working mode (upper right of screen)
F6: Moves to the next page
F7: Returns to the previous page
REMARK
For the items not displayed in “Pre-defined Mon”, you can freely select and check from “Pre-defined Moni-
toring” items.

TABLE OF PRE-DEFINED MONITORING ITEMS

Pre-defined Monitoring (01/14) Machine basics (1)
Unit Applicable
No. ID Item name
SI Metric Imperial component

1 01002 Engine Speed r/min rpm rpm ENG

2 04107 Coolant Temperature °C °C ℉ ENG
3 18400 Intake Manf. Temp. °C °C ℉ ENG
4 03203 Battery Power supply V V V ENG

Pre-defined Monitoring (02/14) Machine basics (2)

Unit Applicable
No. ID Item name
SI Metric Imperial component

1 01002 Engine Speed r/min rpm rpm ENG

2 37502 Ambient Air Temp. °C °C ℉ ENG
3 14200 Fuel Temperature °C °C ℉ ENG
4 63400 Exh.manif.Gas Temp. °C °C ℉ ENG

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30 TESTING AND ADJUSTING SET AND OPERATE MACHINE MONITOR

Pre-defined Monitoring (03/14) Fuel injection system

Unit Applicable
No. ID Item name
SI Metric Imperial component

1 01002 Engine Speed r/min rpm rpm ENG

2 36400 Rail Pressure MPa kg/cm2 psi ENG
3 14200 Fuel Temperature °C °C ℉ ENG
4 63400 Exh.manif.Gas Temp. °C °C ℉ ENG

Pre-defined Monitoring (04/14) EGR actuator

Unit Applicable
No. ID Item name
SI Metric Imperial component

1 01002 Engine Speed r/min rpm rpm ENG

2 04107 Coolant Temperature °C °C ℉ ENG
3 62900 EGR V. Target Posn. STEP STEP STEP ENG
4 18100 EGR V. Actual Posn. STEP STEP STEP ENG

Pre-defined Monitoring (05/14) Intake air actuator

Unit Applicable
No. ID Item name
SI Metric Imperial component

1 01002 Engine Speed r/min rpm rpm ENG

2 04107 Coolant Temperature °C °C ℉ ENG
3 62701 Eng. Throt. Command % % % ENG
4 62700 IntakeThrot.Position % % % ENG

Pre-defined Monitoring (06/14) Engine temperature

Unit Applicable
No. ID Item name
SI Metric Imperial component

1 01002 Engine Speed r/min rpm rpm ENG

2 04107 Coolant Temperature °C °C ℉ ENG
3 18400 Intake Manf. Temp. °C °C ℉ ENG
4 48500 EGR Temperature °C °C ℉ ENG

Pre-defined Monitoring (07/14) Intake and exhaust pressure

Unit Applicable
No. ID Item name
SI Metric Imperial component

1 01002 Engine Speed r/min rpm rpm ENG

2 37400 Ambient Pressure kPa kg/cm2 psi ENG

3 64000 Air Inlet Pressure kPa kg/cm2 psi ENG

4 48300 Act.Exh.Manf.Press. kPa kg/cm2 psi ENG

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SET AND OPERATE MACHINE MONITOR 30 TESTING AND ADJUSTING

Pre-defined Monitoring (08/14) Aftertreatment system (1)

Unit Applicable
No. ID Item name
SI Metric Imperial component

1 01002 Engine Speed r/min rpm rpm ENG

2 04107 Coolant Temperature °C °C ℉ ENG
3 47100 KDPF Differential Pressure kPa kg/cm2 psi KDPF

4 63700 KDPF Inlet Pressure kPa kg/cm2 psi KDPF

Pre-defined Monitoring (09/14) Aftertreatment system (2)

Unit Applicable
No. ID Item name
SI Metric Imperial component

1 01002 Engine Speed r/min rpm rpm ENG

2 04107 Coolant Temperature °C °C ℉ ENG
3 47400 KDPF Intmdt.GasTemp. °C °C ℉ KDPF
4 47300 KDPF Intake GasTemp. °C °C ℉ KDPF

Pre-defined Monitoring (10/14) Aftertreatment system (3)

Unit Applicable
No. ID Item name
SI Metric Imperial component

1 01002 Engine Speed r/min rpm rpm ENG

2 04107 Coolant Temperature °C °C ℉ ENG
3 18100 EGR V. Actual Posn. STEP STEP STEP ENG
4 62700 IntakeThrot.Position % % % ENG

Pre-defined Monitoring (11/14) pump basics

Unit Applicable
No. ID Item name
SI Metric Imperial component

1 01002 Engine Speed r/min rpm rpm ENG

2 01300 PC-EPC solenoid current mA mA mA MCN
3 01141 Service Press. Sens1 MPa kg/cm2 psi MCN

4 01142 Service Press. Sens2 MPa kg/cm2 psi MCN

Pre-defined Monitoring (12/14) PPC pressure (1)

Unit Applicable
No. ID Item name
SI Metric Imperial component

1 01002 Engine Speed r/min rpm rpm ENG

2 65400 Pressure Switch, Work Equipment ON/OFF ON/OFF ON/OFF MCN
3 01141 Service Press. Sens1 MPa kg/cm2 psi MCN

4 01142 Service Press. Sens2 MPa kg/cm2 psi MCN

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30 TESTING AND ADJUSTING SET AND OPERATE MACHINE MONITOR

Pre-defined Monitoring (13/14) PPC pressure (2)

Unit Applicable
No. ID Item name
SI Metric Imperial component

1 01002 Engine Speed r/min rpm rpm ENG

2 09000 Swing PPC Pressure MPa kg/cm2 psi MCN

3 01141 Service Press. Sens1 MPa kg/cm2 psi MCN

4 01142 Service Press. Sens2 MPa kg/cm2 psi MCN

Pre-defined Monitoring (14/14) PPC pressure (3)

Unit Applicable
No. ID Item name
SI Metric Imperial component

1 01002 Engine Speed r/min rpm rpm ENG

2 07101 Travel PPC pressure MPa kg/cm2 psi MCN

3 01141 Service Press. Sens1 MPa kg/cm2 psi MCN

4 01142 Service Press. Sens2 MPa kg/cm2 psi MCN

METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION

The machine monitor can monitor the condition of the machine in real time by receiving signals from various
switches, sensors, and actuators installed to various parts of the machine and the information from the control-
lers which is controlling them.
“Self-define Monitoring” is used to select a desired monitoring item.
1. Select “Self-define Monitoring” on “Service Menu” screen.

2. When “Monitoring Selection Menu” screen is displayed,

use the function switch to select items to be monitored.
F1: Moves the selection down by one item
F2: Moves the selection up by one item
F3: Returns the screen to “Service Menu” screen
F4: Enters the selection
F6: Moves the selection leftward
F7: Moves the selection rightward
F8: Changes the screen to “ID Input” screen.
• Setting of the monitoring changes to “ENG”→“KDPF”→“MCN”→“MON”→“ENG” in this order when
function switch F7 is pressed. (When F6 is pressed, it happens in the reverse order.)
• Selection with function switches: Select an applicable equipment by using F6 or F7, select an item by
using F1 or F2, and then enter it by using F4.

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SET AND OPERATE MACHINE MONITOR 30 TESTING AND ADJUSTING

• If you press function switch F8 and input ID on Self-

define Monitoring screen, the monitoring item is se-
lected directly.
F1: Decreases the number by 1
F2: Increases the number by 1
F3: Cancels the input and returns to “Self-define Moni-
toring” screen
F4: Enters the input value
F6: Moves the selection leftward
F7: Moves the selection rightward
• If the color of the selected box changes from yellow to red, the selection of the item of that box is en-
tered.
• 4 monitoring items at maximum can be selected at the same time. However, it may not be possible to
set up to 4 items depending on the display pattern of the selected items.
3. After selecting monitoring items, use the function switch to
execute the monitoring.
• Execution with function switch: Double click or keep
pressing F4 for approximately 2 seconds.
• When performing monitoring by inputting ID, input ID
first, then input “99999” with the function switch, and
enter with F4.
F1: Decreases the number by 1
F2: Increases the number by 1
F3: Cancels the input and returns to “Self-define Moni-
toring” screen
F4: Enters the input value
F6: Moves the selection leftward
F7: Moves the selection rightward
• If monitoring items are selected up to the limit number, monitoring is executed automatically.
REMARK
When performing monitoring of only two items, select each item, and confirm them with F4. If F4 is pressed
once again, monitoring is executed.
4. On “Monitoring” screen, perform the necessary operation
of the machine and check the monitoring information.
REMARK
• Monitoring information is indicated by value, ON/OFF,
or special display.
• The unit of display can be selected in “SI” unit, “Metric”
unit, or “Imperial” unit with “Default” function in service
mode.

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30 TESTING AND ADJUSTING SET AND OPERATE MACHINE MONITOR

5. You can hold and release holding of the monitoring infor-

mation by using the function switches.
F1: Selects Display of Non-display of auto-deceleration pi-
lot lamp
F2: Selects HOLD or releasing HOLD (If HOLD is selected,
HOLD part is hatched)
F3: Return the screen to Self-define Monitoring screen
F5: Changes the working mode (upper right of screen)
F7: Saves the currently displayed monitoring item
6. To change the setting of the working mode, travel speed,
or auto-deceleration during monitoring, operate the corre-
sponding switch under the current condition, and the corre-
sponding mode is selected.
REMARK
If the setting is changed during monitoring, the new setting
is held even after the screen returns to the normal screen
after monitoring is finished.

7. Selected monitoring item can be saved and deleted with

function switches.
F6: Clears the monitoring item
F7: Saves the monitoring item
• If any item is saved, “Display the memorized items?”
appears as a confirmation screen when “Self-define
Monitoring” is selected in “Service Menu”. Press F4,
the screen changes to “Monitoring” screen for the
saved monitor item.
• When an item is saved, it can be displayed as many
times as required unless it is cleared.
• If another item is saved while having the previous item
saved, the previously saved item is overwritten by the
latest one.
• If saved monitoring items need to be deleted, press F6
and then press F4 to confirm operation.

TABLE OF SELF-DEFINE MONITORING

Unit Applicable
Code
Monitoring item (display on the screen) compo- Remarks
No. SI Metric Imperial nent
01009 Eng's Dsrd.Opr.Spd. r/min rpm rpm ENG
62100 Target Engine Speed r/min rpm rpm ENG
01002 Engine Speed r/min rpm rpm ENG
04107 Coolant Temperature °C °C ℉ ENG
03203 Battery Power supply V V V ENG
62400 Oil Pressure SW ON/OFF ENG

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SET AND OPERATE MACHINE MONITOR 30 TESTING AND ADJUSTING

Unit Applicable
Code
Monitoring item (display on the screen) compo- Remarks
No. SI Metric Imperial nent
36400 Rail Pressure MPa kg/cm2 psi ENG

37400 Ambient Pressure kPa kg/cm2 psi ENG

37502 Ambient Air Temp. °C °C ℉ ENG
18400 Intake Manf. Temp. °C °C ℉ ENG
64000 Air Inlet Pressure kPa kg/cm2 psi ENG
63400 Exh.manif.Gas Temp. °C °C ℉ ENG
48500 EGR Temperature °C °C ℉ ENG
48300 Act.Exh.Manf.Press. kPa kg/cm2 psi ENG

62300 EGR Diff. Pressure kPa kg/cm2 psi ENG

62900 EGR V. Target Posn. STEP STEP STEP ENG
18100 EGR V. Actual Posn. STEP STEP STEP ENG
14200 Fuel Temperature °C °C ℉ ENG
31701 Accelerator Position % % % ENG
62701 Eng. Throt. Command % % % ENG
62700 IntakeThrot.Position % % % ENG
63200 Basic Inj. Timing CA CA CA ENG
63201 Terget Inj. Amount mm3/st mm3/st mm3/st ENG
63300 Pre Inj. Amount mm3/st mm3/st mm3/st ENG
63301 Main Inj. Amount mm3/st mm3/st mm3/st ENG
63000 After Inj. Amount mm3/st mm3/st mm3/st ENG
63100 Post Inj. Amount mm3/st mm3/st mm3/st ENG
14300 Total Fuel Used L L L ENG
37300 Instantaneous Fuel Consumption ℓ/h ℓ/h gal/h ENG (*1)
62500 Total Inj. Amount mm3/st mm3/st mm3/st ENG
62003 Engine ECU MSW P/N - - - ENG
62004 Engine ECU MAP P/N - - - ENG
62002 Engine ECU No. - - - ENG
62001 Engine Serial No. - - - ENG
62005 Engine ECU S/N - - - ENG
62000 Engine Model No. - - - ENG
63700 KDPF Inlet Pressure kPa kg/cm2 psi KDPF

47100 KDPF Differential Pressure kPa kg/cm2 psi KDPF

47300 KDPF Intake GasTemp. °C °C ℉ KDPF
47400 KDPF Intmdt.GasTemp. °C °C ℉ KDPF
47800 KDPF AshAccumulation g/L g/L g/gal KDPF
47700 KDPF Amount of PM(C) g/L g/L g/gal KDPF
63800 KDPF Amount of PM(P) g/L g/L g/gal KDPF

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30 TESTING AND ADJUSTING SET AND OPERATE MACHINE MONITOR

Unit Applicable
Code
Monitoring item (display on the screen) compo- Remarks
No. SI Metric Imperial nent
04200 Fuel Level Sensor Voltage V V V MCN
01601 2nd Eng Spd. Command r/min rpm rpm MCN
09000 Swing PPC Pressure MPa kg/cm2 psi MCN

07101 Travel PPC pressure MPa kg/cm2 psi MCN

01300 PC-EPC solenoid current mA mA mA MCN
03200 Battery Voltage V V V MCN
01602 2nd Eng. Spd.Command % % % MCN
13113 Main Pump Absorb Torque Nm kgm lbft MCN
Only model
with 1st-line
01701 ATT Sol2 Current mA mA mA MCN attachment
proportional
switch
Only model
with 1st-line
01702 ATT Sol3 Current mA mA mA MCN attachment
proportional
switch
Only model
with 1st-line
01703 ATT Sol4 Current mA mA mA MCN attachment
proportional
switch
Only model
with 1st-line
01704 ATT Sol5 Current mA mA mA MCN attachment
proportional
switch
Only model
with 1st-line
42008 LeverPot.1 Volt Main V V V MCN attachment
proportional
switch
Only model
with 1st-line
42009 LeverPot.1 Volt Sub V V V MCN attachment
proportional
switch
Only model
with 2nd-line
42010 LeverPot.2 Volt Main V V V MCN attachment
proportional
switch
Only model
with 2nd-line
42011 LeverPot.2 Volt Sub V V V MCN attachment
proportional
switch

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SET AND OPERATE MACHINE MONITOR 30 TESTING AND ADJUSTING

Unit Applicable
Code
Monitoring item (display on the screen) compo- Remarks
No. SI Metric Imperial nent
Only model
with 1st-line
42012 Lever Pot.1 Stroke % % % MCN attachment
proportional
switch
Only model
with 2nd-line
42013 Lever Pot.2 Stroke % % % MCN attachment
proportional
switch
01141 Service Press. Sens1 MPa kg/cm2 psi MCN

01142 Service Press. Sens2 MPa kg/cm2 psi MCN

Travel ON/OFF MCN
01900 Pressure SW 1 Swing or Arm IN ON/OFF MCN
Work Equipment ON/OFF MCN
02300 Solenoid 1 Travel Speed ON/OFF MCN
02301 Solenoid 2 PPC lock relay ON/OFF MCN
Controller Out-
03701 Travel Alarm ON/OFF MCN
put 1
Key SW ON/OFF MCN
02200 SW Input 1
Start ON/OFF MCN
Lock Lever SW ON/OFF MCN
Lock Lever SW 2 ON/OFF MCN

02203 SW Input 2 PPC Lock Solenoid

ON/OFF MCN
State
lock lever automatic lock
ON/OFF MCN
cancel switch
Only model
with 1st-line
02202 SW Input 3 Breaker Sw ON/OFF MCN attachment
proportional
switch
Model Selection 1 ON/OFF MCN
02201 SW Input 5
Model Selection 2 ON/OFF MCN
20294 MCN Con. Ass'y P/N - - - MCN
20430 MCN Con. Serial No - - - MCN
20295 MCN Con. Prog. P/N - - - MCN
20296 MCN Con. Prog. Ver - - - MCN
Key SW ON/OFF MON
04500 Monitor Input 1
ENG Shtdwn Secondary ON/OFF MON

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30 TESTING AND ADJUSTING SET AND OPERATE MACHINE MONITOR

Unit Applicable
Code
Monitoring item (display on the screen) compo- Remarks
No. SI Metric Imperial nent
F1 ON/OFF MON

Monitor 1st F2 ON/OFF MON

04507
Switches F3 ON/OFF MON
F4 ON/OFF MON
F5 ON/OFF MON

Monitor 2nd F6 ON/OFF MON

04508
Switches F7 ON/OFF MON
F8 ON/OFF MON
20227 Assembly P/N (MON) - - - MON
20402 Serial No. (MON) - - - MON
20228 Software P/N (MON) - - - MON
20200 Application (MON) - - - MON
20260 AssemblyP/N(KOMTRAX) - - - MON
20418 KOMTRAX S/N - - - MON
20261 SoftwareP/N(KOMTRAX) - - - MON
20273 KOMTRAX Prog.Version - - - MON
20262 Assembly P/N (IDKey) - - - MON
20419 Serial No. (IDKey) - - - MON
20263 Software P/N (IDKey) - - - MON

• Listing order in table

The monitoring items are listed in the order of the display on Monitoring Selection Menu screen.
• Unit
The display unit can be set to “SI”, “Metric”, or “Imperial” as required (select a desired unit from “Unit” of
“Default” in Service Menu).
“mm3/st” in the display unit is an abbreviation for mm3/stroke.
• Applicable component
ENG: The engine controller detects the monitoring information.
KDPF: The engine controller detects the monitoring information of KDPF.
MCN: The machine controller detects the monitoring information.
MON: The machine monitor detects the monitoring information.
*1: “Instantaneous Fuel Consumption” (Code No.: 37300) is the theoretical fuel consumption ratio. (Since it is a
theoretical value, it is slightly different from the actual fuel consumption ratio.)

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SET AND OPERATE MACHINE MONITOR 30 TESTING AND ADJUSTING

ABNORMALITY RECORD MENU

METHOD FOR CONFIRMING ABNORMALITY RECORD (MECHANICAL SYS-
TEMS)
The machine monitor logs the failures that occurred in the past and is occurring currently. It classifies them into
the mechanical system abnormality and electrical system abnormality.
Check the information about “Mechanic Sys Error Record” by performing the following procedures.
For the failure code list, see “FAILURE CODES TABLE” for troubleshooting.
1. Select “Abnormality Record” on “Service Menu” screen.
REMARK
For the selection method, see “Operating method of serv-
ice mode” in “SERVICE MODE”.

2. On “Abnormality Record” screen, select “Mechanic Sys Er-

ror Record” with the function switch.
F1: Moves the selected item down by one item
F2: Moves the selected item up by one item
F3: Returns the display to the “Service Menu” screen
F4: Enters the selected item
F8: Moves to the code entry screen

3. Check the following information on “Mechanic Sys Error

Record” screen.
a: Occurrence order from the latest one/ Total number of
records
b: Failure code
c: Detail of failure
d: Number of occurrences (displayable range: 0 to 65535
times)
e: Service meter reading at the first occurrence
f: Service meter reading at the last occurrence
F1: Moves the selected item down by one item
F2: Moves the selected item up by one item
F3: Returns to “Abnormality Record” screen

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30 TESTING AND ADJUSTING SET AND OPERATE MACHINE MONITOR

REMARK
• If no abnormality is recorded, “No Abnormality Record” is displayed.
• In the mechanical systems abnormality record screen, up to 20 cases currently stored are displayed.
• If the number of occurrence is 1 (first occurrence), the service meter reading at the first occurrence and
that at the last occurrence are the same. When the latest service meter reading is recovered, the value
at the recovery time is displayed, thus the above readings may not be the same.
• If “E” is displayed on the left of a failure code, the abnormality is still occurring or correction of it is not
confirmed.
• For all of the failure codes that the machine monitor can record, see Troubleshooting, “Failure code list”.
• If the message of the failure code is too long, the rest of the message is scrolled.
• The contents of an abnormality record of the mechanical system cannot be deleted.

METHOD FOR CONFIRMING ABNORMALITY RECORD (ELECTRICAL SYSTEMS)

The machine monitor logs the failures that occurred in the past and is occurring currently. It classifies them into
the mechanical system abnormality and electrical system abnormality.
To check “Electric Sys Error Record”, perform the following procedures.
For all of the failure codes that the machine monitor can record, see TROUBLESHOOTING, “FAILURE CODES
TABLE”.
1. Select “Abnormality Record” on “Service Menu” screen.
REMARK
For the selection method, see “Operating method of serv-
ice mode” in “SERVICE MODE”.

2. On “Abnormality Record” screen, select “Electric Sys Error

Record” with the function switch.
F1: Moves the selected item down by one item
F2: Moves the selected item up by one item
F3: Returns the display to the “Service Menu” screen
F4: Enters the selected item
F8: Moves to the code entry screen

3. Check the following information on “Electric Sys Error Re-

cord” screen.
a: Occurrence order from the latest one/ Total number of
records
b: Failure code
c: Detail of failure
d: Number of occurrences (displayable range: 0 to 65535
times)
e: Service meter reading at the first occurrence
f: Service meter reading at the last occurrence
F1: Moves the selected item down by one item
F2: Moves the selected item up by one item

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SET AND OPERATE MACHINE MONITOR 30 TESTING AND ADJUSTING

F3: Returns the screen to “Abnormality Record” screen

REMARK
• If no abnormality is recorded, “No Abnormality Record” is displayed.
• The screen shows 20 cases of the electrical systems abnormality which currently stored in the system.
If the number of cases exceeds 21, the monitor displays the latest occurrence code and deletes the old-
est case.
• If the number of occurrence is 1 (first occurrence), the service meter reading at the first occurrence and
that at the last occurrence are the same.
• If “E” is displayed on the left of a failure code, the abnormality is still occurring or correction of it is not
confirmed.
• For all of the failure codes that the machine monitor can record, see Troubleshooting, “Failure code list”.
• If the message of the failure code is too long, the rest of the message is scrolled.
4. Delete the information about abnormality record by per-
forming the following operations with the function switches
while “Electric Sys Error Record” screen is displayed.
1) Switch operation (While pressing F8, press other
switches in order): F8 + F1 → F2 → F3

2) Check that the display on the screen becomes the de-

lete mode, then clear the individual information one by
one or all together by using the function switches.
REMARK
The screen is in delete mode if “CLEAR” is displayed
above F8.
F1: Moves the selected item down by one item
F2: Moves the selected item up by one item
F3: Returns the screen to “Abnormality Record”
screen
F4: Executes the deletion of the selected abnormality records.
F8: Executes the deletion of all the abnormality records.
REMARK
• To delete a selected abnormality record, select the abnormality record with F1 or F2, and then
press F4 to execute the deletion of abnormality record.
• To clear all abnormality records together, press F8, and then all the records are deleted regardless
of the selected item.
• If “E” is displayed on the left of a failure code, the clearing operation is received but the information
is not cleared.
3) After the “Electri Sys Error Record Reset” screen is displayed, operate the function switches to delete
all the records.
F3: Returns to “Electric Sys Error Record” (Delete mode)
F4: Executes the deletion

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30 TESTING AND ADJUSTING SET AND OPERATE MACHINE MONITOR

REMARK
• This is the screen when a selected abnormality re-
cord is going to be deleted.

• This is the screen when all the abnormality records

are going to be deleted.

4) When the screen to notify the completion of the deletion is displayed and then “Electric Sys Error Re-
cord” (Delet mode) screen is displayed, the deletion of the selected abnormality record is completed.
REMARK
• This is the screen displayed when the deletion of a
selected abnormality record is completed.

• This is the screen displayed when the deletion of

all abnormality records is completed.

METHOD FOR CONFIRMING MAINTENANCE RECORD

The machine monitor records the maintenance information of the filters, oils, etc., which are displayed and
checked by the following operations.
If the data are reset in the operator mode when the maintenance is performed, the number of the times of main-
tenance is recorded here.

PC45MR-5, PC55MR-5 30-125

SET AND OPERATE MACHINE MONITOR 30 TESTING AND ADJUSTING

1. Select “Maintenance Record” on “Service Menu” screen.

2. When the “Maintenance Record” screen is displayed, use

the function switch to select the confirmation item.
F1: Moves the selection down by one item
F2: Moves the selection up by one item
F3: Returns the screen to “Service Menu” screen
F8: Changes the screen to Code Input screen.
REMARK
Method of selecting is similar to “Service Menu” screen.

The following items can be selected on Maintenance Record

Code Item
49 Air Cleaner Clean and Change
60 Coolant Change
41 Fuel Prefilter Change
01 Engine Oil Change
02 Engine Oil Filter Change
05 Hyd Oil Tank Breather Change
03 Fuel Main Filter Change
04 Hydraulic Oil Filter Change
08 Final Drive Case Oil Change
10 Hydraulic Oil Change
48 KDPF Filter Cleaning
Items displayed on Maintenance Record screen
a: Maintenance items
b: Number of replacements up to now
c: Service meter reading (SMR) at the last replacement
d: Current service meter reading (SMR)

METHOD FOR OPERATING MAINTENANCE MODE SETTING

Following can be changed from the menu screen. Enable or disable the function of maintenance items and set
the replacement interval of maintenance items.
• Enable or disable the function of maintenance items.

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30 TESTING AND ADJUSTING SET AND OPERATE MACHINE MONITOR

• To change the replacement interval setting of maintenance items (by item).

• To initialize all of the replacement interval setting of maintenance items.
1. Select “Maintenance Mode Setting” on “Service Menu”
screen.

2. When the “Maintenance Mode Setting” screen is dis-

played, use the function switch to select items to be modi-
fied.
F1: Moves the selection down by one item
F2: Moves the selection up by one item
F3: Returns the screen to “Service Menu” screen
F4: Enters the selection
F8: Changes the screen to Code Input screen.
REMARK
Method of selecting is similar to “Service Menu” screen.

The following items can be selected on Maintenance Mode Setting:

Code Item
00 Maintenance Mode Change
49 Air Cleaner Cleaning or Change
60 Coolant Change
41 Fuel Prefilter Change
01 Engine Oil Change
02 Engine Oil Filter Change
05 Hyd Oil Tank Breather Change
03 Fuel Main Filter Change
04 Hydraulic Oil Filter Change
08 Final Drive Case Oil Change
10 Hydraulic Oil Change
99 All Default Value

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SET AND OPERATE MACHINE MONITOR 30 TESTING AND ADJUSTING

3. Select “Maintenance Mode Change”. The screen is shifted

by selecting “Maintenance Mode On/Off”. Select “ON” or
“OFF”.
ON: Functions of all maintenance items become effective
in operator mode
OFF: Functions of all maintenance items become ineffec-
tive in operator mode
F1: Moves the selection down by one item
F2: Moves the selection up by one item
F3: Cancels the selection and returns the screen to the
“Maintenance Mode Setting” screen
F4: Enters the selection and returns the screen to “Maintenance Mode Setting” screen
REMARK
Even if ON/OFF of each item has been set, if the above setting is changed, it overrides the individual set-
ting.
4. Select “Maintenance Notice Time Setting” and when
“Maintenance Notice Time Setting” screen is displayed,
perform the setting with the function switches.
Default value: Maintenance notice time set on the machine
monitor (Recommended by the manufacturer and not
changeable).
Set value: Maintenance interval that can be freely set.
Maintenance reminder function works according to this set
time in operator mode (the time increases or decreases in
units of 10 h).
F1: Decreases the set value
F2: Increases the set value
F3: Cancels the selection and returns the screen to the
“Maintenance Mode Change” screen
F4: Enters the set value and returns the screen to “Mainte-
nance Mode Change” screen.
F8: Cancels unconfirmed contents of settings
REMARK
• After pressing F4 and confirming the value,the screen
returns to “Maintenance Mode Change” screen.
• If the value of an item which is set to “ON” is changed
after more than 1 h from the setup, the change is rec-
ognized as a reset operation.
5. Select one of each maintenance item and when the each
maintenance item screen is displayed, select “On or Off
Setting”.
F1: Moves the selection down by one item
F2: Moves the selection up by one item
F3: Cancels the selection and returns the screen to the
“Maintenance Mode Setting” screen
F4: Enters the selection and proceeds to “ON” or “OFF”
setting of each maintenance item
F8: Changes the screen to Code Input screen.

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30 TESTING AND ADJUSTING SET AND OPERATE MACHINE MONITOR

REMARK
• Displayed screen is an example of “Engine Oil Change”.
• Method of selecting is similar to “Service Menu” screen.
6. When each maintenance item screen is displayed, select
“ON” or “OFF” with function switches.
“ON”: Function of the particular maintenance item be-
comes effective in “operator mode”.
“OFF”: Function of the particular maintenance item be-
comes ineffective in “operator mode”.
F1: Moves the selection down by one item
F2: Moves the selection up by one item
F3: Cancels the selection and returns the screen to each
maintenance item screen.
F4: Enters the setting and returns the screen to each maintenance item screen.
7. Select “Set” of each maintenance item. When the screen
of each maintenance item is displayed, perform the setting
with the function switches.
Default value: Maintenance notice time set on the machine
monitor (Recommended by the manufacturer and not
changeable).
Set value: Maintenance interval that can be freely set.
Maintenance reminder function works according to this set
time in operator mode (the time increases or decreases in
units of 25 h).
F1: Decreases the set value
F2: Increases the set value
F3: Cancels the set value and returns the screen to each
maintenance item screen.
F4: Enters the set value and returns the screen to each
maintenance item screen.
F8: Cancels unconfirmed contents of settings
REMARK
• After pressing F4 and confirming the value, the screen
returns to maintenance item screen.
• If the value of an item which is set to “ON” is changed
after more than 1 h from the setup, the change is rec-
ognized as a reset operation.

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SET AND OPERATE MACHINE MONITOR 30 TESTING AND ADJUSTING

8. The screen is shifted by selecting “All Default Value”, per-

form the setting with the function switches.
If the operation for this function is executed, the set values
of all the maintenance items return to the default values.
F3: Returns the screen to “Maintenance Mode Setting”
screen.
F4: Executes initialization.
REMARK
Press F4, and the initialization completion screen is dis-
played after a short while. When “Maintenance Mode Set-
ting” screen is displayed, initialization has completed.

METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING

The telephone number can be displayed together with “Current Abnormality” in the operator mode. Phone num-
ber can be registered and changed according to the following procedure.
Phone number must be registered in order to display the number while in operator mode.
1. Select “Phone Number Entry” from the “Service Menu”
screen.
REMARK
For the selection method, see “Operating method of serv-
ice mode” in “SERVICE MODE”.

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30 TESTING AND ADJUSTING SET AND OPERATE MACHINE MONITOR

2. On “Phone Number Entry” screen, register/correct the

phone number with the function switches.
F1: Number gets smaller
F2: Number gets larger
F3: Returns the display to the “Service Menu” screen
F4: Enters the input.
F6: Moves the input position to the next left place (if not
blank).
F7: Moves the input position to the right (if not blank)
F8: Deletes all the numbers.
REMARK
• Up to 14 digits can be inputted from the left. Leave the
surplus places without inputting any digit.
• If an inputted numeral is wrong, move the cursor (or-
ange background) to that digit and overwrite it with the
correct numeral.
• If the phone number is not registered, no phone num-
ber is displayed in the operator mode when F4 is
pressed.

PC45MR-5, PC55MR-5 30-131

SET AND OPERATE MACHINE MONITOR 30 TESTING AND ADJUSTING

DEFAULT MENU
METHOD FOR SETTING WITH DEFAULT SETTING MENU (KEY-ON MODE)
Default menu is used to check or change default values of the machine monitor and machine.
Use "Key-on Mode" to set the working mode selected and displayed on the machine monitor when the starting
switch is turned to ON position.
1. Select “Default” from the “Service Menu” screen.
REMARK
Selecting method is the same as on “Service Menu”
screen.

2. On “Default” screen, select “Key-on Mode” with the func-

tion switch.
F1: Moves the selected item down by one item
F2: Moves the selected item up by one item
F3: Returns the display to the “Service Menu” screen
F4: Enters the selected item
F8: Moves to the code entry screen

3. On the “Key-on Mode” screen, select the mode to be set

with the function switches.
F1: Moves the selected item down by one item
F2: Moves the selected item up by one item
F3: Cancels the selection and returns the screen to “De-
fault” screen
F4: Enters the selected item and returns the screen to “De-
fault” screen
“Power Mode”: monitor displays “P” when the starting
switch is turned on
“Economy Mode”: monitor displays “E” when the starting switch is turned on
“Attachment-P Mode”: monitor displays “ATT/P” (if attachment is installed) when the starting switch is
turned on
“Attachment-E Mode”: monitor displays “ATT/E” (if attachment is installed) when the starting switch is
turned on
“Mode at Previous Key-off”: monitor displays the mode which used from the previous operation when the
starting switch is turned on
REMARK
• Default setting at shipment is “Mode at Previous Key-off”.
• If "With Attachment" is not selected, “Attachment-P Mode” and “Attachment-E Mode” are unselectable.
• If the attachment setting is changed to "without attachment" when either “Attachment-P Mode” or “At-
tachment-E Mode” is selected, the monitor displays P(“Power Mode”).
• If the engine is stopped during operator mode when “Breaker Mode” is selected, the monitor displays
“Breaker Mode” (“B”) regardless of the setting.

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30 TESTING AND ADJUSTING SET AND OPERATE MACHINE MONITOR

METHOD FOR SETTING WITH DEFAULT SETTING MENU (UNIT)

Default menu is used to check or change default values of the machine monitor and machine.
The unit selecting function is used to select units of data displayed for monitoring, etc.
1. Select “Default” from the “Service Menu” screen.
REMARK
For the selection method, see “Operating method of serv-
ice mode” in “SERVICE MODE”.

2. On “Default” screen, select “Unit” with the function switch.

F1: Moves the selected item down by one item
F2: Moves the selected item up by one item
F3: Returns the display to the “Service Menu” screen
F4: Enters the selected item
F8: Moves to the code entry screen

3. On the “Unit” screen, select the unit to be set with the func-
tion switches.
F1: Moves the selected item down by one item
F2: Moves the selected item up by one item
F3: Cancels the selection and returns the screen to “De-
fault” screen
F4: Enters the selected item and returns the screen to “De-
fault” screen

METHOD FOR SETTING WITH DEFAULT SETTING MENU (WITH/WITHOUT AT-

TACHMENT)
Default menu is used to check or change default values of the machine monitor and machine.
Use the sub menu of "With/Without Attachment" to configure attachment setting when the attachment is instal-
led or removed.
The settings can be changed if the machine is equipped with proportional lever.
1. Select “Default” from the “Service Menu” screen.
REMARK
For the selection method, see “Operating method of serv-
ice mode” in “SERVICE MODE”.

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SET AND OPERATE MACHINE MONITOR 30 TESTING AND ADJUSTING

2. On “Default” screen, select “With/Without Attachment” with

the function switch.
F1: Moves the selected item down by one item
F2: Moves the selected item up by one item
F3: Returns the display to the “Service Menu” screen
F4: Enters the selected item
F8: Moves to the code entry screen
REMARK
Attachment function does not appear on the screen except
for machine equipped with proportional lever.
3. On “With/Without Attachment” screen, select a setting with
the function switch.
Without attachment: When attachment is not installed
With 1 attachment: When 1 attachment is installed
With 2 attachment: When 2 attachment is installed
F1: Moves the selected item down by one item
F2: Moves the selected item up by one item
F3: Cancels the selection and returns the screen to “De-
fault” screen
F4: Enters the selected item and returns the screen to “Default” screen
REMARK
When an attachment is installed, if this setting is not configured correctly, the attachment setting in the oper-
ator mode cannot be performed. As a result, the attachment may not work normally or the hydraulic compo-
nents may be damaged.

METHOD FOR SETTING WITH DEFAULT SETTING MENU (AUTO IDLE STOP TIM-
ER FIXING)
Default menu is used to check or change default values of the machine monitor and machine.
Auto idle stop timer fixing function sets the selectable time on “Auto Idle Stop Timer Set” in the operator mode.
1. Select “Default” from the “Service Menu” screen.
REMARK
For the selection method, see “Operating method of serv-
ice mode” in “SERVICE MODE”.

2. On “Default” screen, select “Auto Idle Stop Time Fixing”

with the function switch.
F1: Moves the selected item down by one item
F2: Moves the selected item up by one item
F3: Returns the display to the “Service Menu” screen
F4: Enters the selected item
F8: Moves to the code entry screen

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30 TESTING AND ADJUSTING SET AND OPERATE MACHINE MONITOR

3. On “Auto Idle Stop Time Fixing” screen, choose the setting

of time with the function switch.
“Flexible”: Set the time (“OFF” to “60 min”) on “Auto Idle
Stop Timer Set” screen in operator mode.
“OFF”: Hide the setting menu of “Auto Idle Stop Timer Set”
screen in operator mode.
x-minute fixing: Turn off the timer or the selected time can-
not be extended on “Auto Idle Stop Timer Set” screen in
the operator mode.
F1: Moves the selected item down by one item
F2: Moves the selected item up by one item
F3: Cancels contents of setting before the entry and returns the screen to “Default” screen
F4: Goes to confirmation screen of “Auto Idle Stop Time Fixing”
REMARK
• If this setting is turned “OFF”, “Auto Idle Stop Timer Set” cannot be performed in operator mode, and the
auto idle stop function does not work.
• The maximum value of the auto idle stop time must be set after checking compliance with the applicable
law, which differs by region.
4. On “Auto Idle Stop Time Fixing” screen, enter the setting
with the function switch.
F3: Cancels and returns the screen to the previous screen
F4: Enters the change

• This is an example of screen when setting changed

successfully.
If the setting changed, the screen returns to “Default”
screen after pressing F4 again.

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SET AND OPERATE MACHINE MONITOR 30 TESTING AND ADJUSTING

• This is an example of screen when your change was

not applied successfully.
When the setting is not applied successfully, the
screen returns to “Auto Idle Stop Time Fixing” screen
after pressing F3.

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30 TESTING AND ADJUSTING SET AND OPERATE MACHINE MONITOR

DIAGNOSTIC TESTS MENU

METHOD FOR OPERATING TESTING MENU (CYLINDER CUT-OUT OPERATION)
Testing menu is used to check the machine or reset the settings of the machine monitor.
Cylinder cutout mode operation means to run the engine with one or more fuel injectors disabled electrically to
reduce the number of effective cylinders. This operation is used to identify a cylinder that does not output power
normally (combustion in it is abnormal).
NOTICE
Do not perform “Cylinder Cutout Mode Operation” while connecting to Smart Assist Direct.
1. Select “Diagnostic Tests” on “Service Menu” screen.

2. When “Diagnostic Tests” screen is displayed, use function

switch to select “Cylinder Cutout Mode Operation”.
REMARK
Method of selecting is similar to “Service Menu” screen.

3. On “Cylinder Cutout Mode Operation” screen, select a cyl-

inder to be cut out with the function switches.
F1: Selects ON/OFF of auto-deceleration function
F2: Selects HOLD or releasing HOLD (If HOLD is selected,
“HOLD” part is hatched)
F3: Returns the screen to “Diagnostic Tests” screen
F4: Enters the selection
F6: Moves the selection leftward
F7: Moves the selection rightward
REMARK
• This operation can be performed while the engine is running.
• If background (a) of the selected cylinder number becomes white after pressing F4, the cylinder is cut-
out.
• If the machine monitor cuts out a cylinder but the engine controller cannot cutout that cylinder, the back-
ground (a) of the cylinder number becomes yellow.
• One or more cylinders can be cutout.
• In Cylinder Cutout Mode Operation, the auto-deceleration function can be selected. When the auto-de-
celeration function is on, auto-deceleration pilot lamp (b) lights up.
• The holding function is available for a cylinder, regardless of whether it is cutout or not.

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SET AND OPERATE MACHINE MONITOR 30 TESTING AND ADJUSTING

If a normally operating cylinder is cut out, the following phenomena occur. If the engine is running at near
high idle, however, the engine speed may not be lowered for the reason of engine control. In this case, low-
er the engine speed with the fuel control dial and judge by increase of the injection rate command with
monitoring code: 62500 “Fuel Injection Rate (Total)”.
• Reduction of engine speed
• Increase of fuel injection rate (total)
4. When changing a cylinder to be cutout or when cylinder cutout operation is finished, select a cutout cylinder
to be reset with the function switches.
NOTICE
The cutout cylinder mode operation is not automatically released after the screen returns to the op-
erator mode. Accordingly, be sure to perform the releasing operation after the cylinder cutout mode
operation is finished.
REMARK
• This operation can be performed while the engine is running.
• If background (a) of the selected cylinder No. becomes blue after pressing F4, the cylinder is reset.
• If the machine monitor releases a cutout cylinder but the engine controller cannot release the cutout cyl-
inder, the background (a) of the cylinder number becomes red.

METHOD FOR OPERATING TESTING MENU (REGENERATION FOR SERVICE)

Testing menu is used to check the machine or reset the settings of the machine monitor.
Active regeneration for service refers to the method of burning soot by performing aftertreatment devices regen-
eration, regardless of the soot accumulation.
NOTICE
Do not perform “Active Regeneration for Service” while connecting to Smart Assist Direct.
1. Select “Diagnostic Tests” on “Service Menu” screen.

2. When the “Diagnostic Tests” screen is displayed, use the

function switch to select “Active Regeneration for Service”.
REMARK
• Method of selecting is similar to “Service Menu”
screen.
• While the Aftertreatment Devices Regeneration status
is in Manual Stationary Regeneration or stopped, “Ac-
tive Regeneration for Service” cannot be selected.

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30 TESTING AND ADJUSTING SET AND OPERATE MACHINE MONITOR

3. When the “Active Regeneration for Service” screen is dis-

played, the following information is displayed correspond-
ing to the Aftertreatment Devices Regeneration condition.
Set the Aftertreatment Devices Regeneration according to
the given messages.
a: Soot accumulation level
b: Aftertreatment devices regeneration status
c: Selectable items
d: Message

4. Select “Manual Stationary Regeneration” on the “Active

Regeneration for Service” screen.
F1: Moves the selection down by one item
F2: Moves the selection up by one item
F3: Returns the screen to “Diagnostic Tests” screen
F4: Enters the selection

5. When “Manual Stationary Regeneration” screen is dis-

played, press F4 to perform the manual stationary regen-
eration.

REMARK
• The active regeneration for service cannot be started before completion of warm-up operation.
• Press F3, the screen returns to “Active Regeneration for Service” screen.
• The screen changes to the “Monitoring Selection Menu” screen which enables monitoring of machine
information during active regeneration by performing the following switch operation during Active Re-
generation for Service:
Switch operation (While pressing F8, press other switches in order): F8 + F1 → F2 → F3
• Press F3 on “Monitoring” screen and the screen returns o the “Active Regeneration for Service” screen.
• For the monitoring operation, see “METHOD FOR CHECKING SELF-DEFINE MONITORING INFOR-
MATION” of “SET AND OPERATE MACHINE MONITOR”.

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SET AND OPERATE MACHINE MONITOR 30 TESTING AND ADJUSTING

• “Active Regeneration for Service” can be performed only when the lock lever is in LOCK position and
the fuel control dial is in the MIN (Low idle) position.
• Before performing Manual Stationary Regeneration, secure the safety of the surroundings, no people
and no combustible are in the area. When the machine needs to be moved again for the sake of securi-
ty, move it to a safe place and repeat the operation from the start.
• “Active Regeneration for Service” stops automatically in about 30 minutes.
• Select “Regeneration Disable” and press F4 during the
manual stationary regeneration. The screen moves to
“Regeneration Disable” screen, and the message of
“Do you stop regeneration?” appears. You can stop by
pressing F4.
After the active regeneration for service is complete, “Re-
generation completed.” is displayed on the screen.
F3: Does not stop regeneration (manual stationary regen-
eration is continued)
F4: Stops regeneration

METHOD FOR OPERATING TESTING MENU (KDPF MEMORY RESET)

Testing menu is used to check the machine or reset the settings of the machine monitor.
“KDPF Memory Reset” resets KDPF information saved in the machine. Refer to this section to reset KDPF
memory when KDPF is cleaned or replaced.
NOTICE
Do not perform “KDPF Memory Reset” while connecting to Smart Assist Direct.
1. Select “Diagnostic Tests” on “Service Menu” screen.

2. On the “Diagnostic Tests” screen, use the function switch

to select “KDPF Memory Reset”.
REMARK
Method of selecting is similar to “Service Menu” screen.

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30 TESTING AND ADJUSTING SET AND OPERATE MACHINE MONITOR

3. On “KDPF Memory Reset” screen, select an item to be re-

set.
F1: Moves the selection down by one item
F2: Moves the selection up by one item
F3: Returns the screen to “Diagnostic Tests” screen
F4: Enters the selection
F8: Changes the screen to Code Input screen.
After cleaning or replacing KDOC, rest “KDOC Change”.

4. After “Do you want to reset?” is displayed, enter the reset

with the function switch.
F3: Returns to the previous screen
F4: Executes resetting

• This is an example of screen when resetting is per-

formed normally.
When resetting is performed normally, if you press F3
again, the screen returns to “Diagnostic Tests” screen.

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SET AND OPERATE MACHINE MONITOR 30 TESTING AND ADJUSTING

• This is an example of screen when resetting fails.

When resetting fails, press F3 and the screen returns
to “KDPF Memory Reset” screen.

METHOD FOR OPERATING TESTING MENU (RAIL PRESSURE MEMORY RESET)

Testing menu is used to check the machine or reset the settings of the machine monitor.
“Rail Pressure Memory Reset” resets the operation information of pressure limiter valve saved in the machine.
Perform this when the common rail assembly or pressure limiter valve is replaced.
NOTICE
Do not perform “Rail Pressure Memory Reset” while connecting to Smart Assist Direct.
1. Select “Diagnostic Tests” on “Service Menu” screen.

2. On the “Diagnostic Tests”, use the function switch to select

“Rail Pressure Memory Reset”.
REMARK
Method of selecting is similar to “Service Menu” screen.

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30 TESTING AND ADJUSTING SET AND OPERATE MACHINE MONITOR

3. When “Rail Pressure Memory Reset” screen is displayed,

select “Common Rail Change”.
F3: Returns the screen to “Diagnostic Tests” screen
F4: Enters the selection

4. After “Do you want to reset?” is displayed, enter the reset

with the function switch.
F3: Returns the screen to “Rail Pressure Memory Reset”
screen
F4: Executes resetting

• This is an example of screen when resetting is per-

formed normally.
When resetting is performed normally, if you press F3
again, the screen returns to “Diagnostic Tests” screen.

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SET AND OPERATE MACHINE MONITOR 30 TESTING AND ADJUSTING

• This is an example of screen when resetting fails.

When resetting fails, if you press F3, the screen re-
turns to “Rail Pressure Memory Reset” screen.

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30 TESTING AND ADJUSTING SET AND OPERATE MACHINE MONITOR

ADJUSTMENT MENU
METHOD FOR ADJUSTING WITH ADJUSTING MENU (PUMP ABSORPTION TOR-
QUE)
Adjustment menu is used to check the various settings of the machine or to adjust the value.
Function of Pump Absorption Torque adjusts the absorption torque of the main pump.
1. Select “Adjustment” on “Service Menu” screen.

2. On “Adjustment” screen, use the function switch to select

“Pump Absorption Torque”.
REMARK
Method of selecting is similar to “Service Menu” screen.

3. After the “Pump Absorption Torque” screen is displayed,

select the desired value at the right side by using the func-
tion switches.
Set value: For the actual torque adjustment value, see ta-
ble.
F1: Decreases the set value
F2: Increases the set value
F4: Checks and enters setting. Returns to “Adjustment”
screen.
REMARK
The 3-digit number in the left column does not change
since it is the code of this function.

Relation between set value and torque adjustment value

Code Set value Torque adjustment value
000 +14.7 Nm {+1.5 kgm}
001 +9.8 Nm {+1 kgm}
002 +4.9 Nm {+0.5 kgm}
021 003 0 Nm {0 kgm}
004 -4.9 Nm {-0.5 kgm}
005 -9.8 Nm {-1 kgm}
006 -14.7 Nm {-1.5 kgm}

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SET AND OPERATE MACHINE MONITOR 30 TESTING AND ADJUSTING

METHOD FOR ADJUSTING WITH ADJUSTING MENU (ATTACHMENT EPC 2 AD-

JUSTMENT)
Adjustment menu is used to check the various settings of the machine or to adjust the value.
“Attachment EPC 2 Adjustment” function adjusts the current of attachment EPC2.
1. From “Service Menu” screen, select “Adjustment”.
REMARK
For the selection method, see “Operating method of serv-
ice mode” in “SERVICE MODE”.

2. On “Adjustment” screen, select “Attachment EPC 2 Adjust-

ment” with the function switches.
F1: Moves the selected item down by one item
F2: Moves the selected item up by one item
F3: Returns the display to the “Service Menu” screen
F4: Enters the selected item
F8: Moves to the code entry screen

3. On “Attachment EPC 2 Adjustment” screen, select the de-

sired value at the right side by using the function switches.
Set value: For the actual adjustment value of attachment
EPC current, see the table.
F1: Decreases the set value
F2: Increases the set value
F4: Checks and enters setting. Returns to “Adjustment”
screen.
REMARK
The 3-digit number in the left column does not change
since it is the code of this function.

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30 TESTING AND ADJUSTING SET AND OPERATE MACHINE MONITOR

Relationship between set value and attachment EPC current adjustment value
Attachment EPC current adjustment
Code Set value
value
000 -100 mA
001 -90 mA
002 -80 mA
003 -70 mA
004 -60 mA
005 -50 mA
006 -40 mA
007 -30 mA
008 -20 mA
009 -10 mA
049 010 0 mA
011 10 mA
012 20 mA
013 30 mA
014 40 mA
015 50 mA
016 60 mA
017 70 mA
018 80 mA
019 90 mA
020 100 mA

METHOD FOR ADJUSTING WITH ADJUSTING MENU (ATTACHMENT EPC 3 AD-

JUSTMENT)
Adjustment menu is used to check the various settings of the machine or to adjust the value.
“Attachment EPC 3 Adjustment” function adjusts the current of attachment EPC3.
1. From “Service Menu” screen, select “Adjustment”.
REMARK
For the selection method, see “Operating method of serv-
ice mode” in “SERVICE MODE”.

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SET AND OPERATE MACHINE MONITOR 30 TESTING AND ADJUSTING

2. On “Adjustment” screen, select “Attachment EPC 3 Adjust-

3. On “Attachment EPC 2 Adjustment” screen, select the de-

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30 TESTING AND ADJUSTING SET AND OPERATE MACHINE MONITOR

Relationship between set value and attachment EPC current adjustment value
Attachment EPC current adjustment
Code Set value
value
000 -100 mA
001 -90 mA
002 -80 mA
003 -70 mA
004 -60 mA
005 -50 mA
006 -40 mA
007 -30 mA
008 -20 mA
009 -10 mA
048 010 0 mA
011 10 mA
012 20 mA
013 30 mA
014 40 mA
015 50 mA
016 60 mA
017 70 mA
018 80 mA
019 90 mA
020 100 mA

METHOD FOR OPERATING BATTERY DISCONNECT SWITCH SETTING

“Batt. Disconnect Set” enables and disables the setting of the system operating lamp. Battery disconnect setting
is valid when the system operating lamp is installed.
NOTICE
• When the setting is invalid, open or short circuit error in system operating lamp cannot be detected
even though the system operating lamp is installed.
• Open circuit error occurs if the system operating lamp is not installed and the setting of battery dis-
connect is valid. Always select the setting of battery disconnect to invalid.
1. Select “Batt. Disconnect Set” on “Service Menu” screen.

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SET AND OPERATE MACHINE MONITOR 30 TESTING AND ADJUSTING

2. After “Batt. Disconnect Set” screen is displayed, select a

setting with the function switch.
F1: Moves the selection down by one item
F2: Moves the selection up by one item
F3: Cancels the selection and the screen returns to “Serv-
ice Menu” screen
F4: Enters the selection and the screen returns to “Service
Menu” screen
3. After entering the selection and retuning the screen to
“Service Menu” screen, turn the starting switch to OFF po-
sition.
When starting switch is turned to OFF position, the setting becomes valid.

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30 TESTING AND ADJUSTING SET AND OPERATE MACHINE MONITOR

KOMTRAX SETTINGS MENU

METHOD FOR CONFIRMING KOMTRAX SETTINGS (TERMINAL STATUS)
The setting and operating state of KOMTRAX can be checked by using the menu of KOMTRAX Settings.
“Terminal Setting State” is used to check the setting condition of the KOMTRAX terminal.
1. Select “KOMTRAX Settings” on “Service Menu” screen.

2. When the “KOMTRAX Settings” screen is displayed, use

the function switch to select “Terminal Status”.
REMARK
Method of selecting is similar to “Service Menu” screen.

3. On “Terminal Status” screen, the following items of infor-

mation are displayed.
Terminal Type: Model name of the KOMTRAX communica-
tion modem
KOMTRAX Communication Inspection: State of radio sta-
tion establishment
GMT time: Greenwich Mean Time (add 9 hours to it for Ja-
pan time)
F3: Returns the screen to “KOMTRAX Settings” screen.

METHOD FOR CONFIRMING KOMTRAX SETTINGS (GPS AND COMMUNICATION

STATUS)
The setting and operating state of KOMTRAX can be checked on KOMTRAX settings screen.
“GPS & Communication Status” is used to check the positioning and communication condition of KOMTRAX ter-
minal.
1. Select “KOMTRAX Settings” on “Service Menu” screen.

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SET AND OPERATE MACHINE MONITOR 30 TESTING AND ADJUSTING

2. When “KOMTRAX Settings” screen is displayed, use the

function switch to select “GPS & Communication State”.
REMARK
Method of selecting is similar to “Service Menu” screen.

3. On the “GPS & Communication Status” screen, the follow-

ing items of information are displayed.
Positioning: GPS positioning state
Communication: Communication environment and connec-
tion state of the communication modem
Number of messages not yet sent: Number of mails that
are saved on the machine monitor and have not yet
been transmitted
F1: Moves the screen to the next page
F2: Returns the screen to the previous page
F3: Returns the screen to “KOMTRAX Settings” screen

METHOD FOR CONFIRMING KOMTRAX SETTINGS (MODEM STATUS)

The setting and operating state of KOMTRAX can be checked by using the menu of KOMTRAX Settings.
“Modem Information” is used to check the phone number and IMSI of the KOMTRAX communication modem.
1. Select “KOMTRAX Settings” on “Service Menu” screen.

2. When the “KOMTRAX Settings” screen is displayed, use

the function switch to select “Modem Information”.
REMARK
Method of selecting is similar to “Service Menu” screen.

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30 TESTING AND ADJUSTING SET AND OPERATE MACHINE MONITOR

3. Display the phone number and IMSI.

F3: Returns the screen to “KOMTRAX Settings” screen

METHOD FOR DISPLAYING SERVICE MESSAGE

Special messages for the technician sent from KOMTRAX base station (a distributor, etc.) can be checked with
this function.
1. Select “Service Message” on “Service Menu” screen.

2. Displaying message
• Displaying message (read only)
If there is a message, its contents are displayed. If
there is no message, “No message.” is displayed.
F1: Moves to the next page (when a message is more
than 2 pages long)
F2: Moves to the previous page (when a message is
more than 2 pages long)
F3: Returns the screen to “Service Menu” screen
REMARK
• The message is different from that sent to the op-
erator in the operator mode.
• This message is only for the technician. Even if a
message is received, the message monitor is not
displayed in the same way as the display in the
operator mode.
• Display of message (with message return function)
When the guidance icon of F4 is displayed, press F4
and display the message reply screen.

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SET AND OPERATE MACHINE MONITOR 30 TESTING AND ADJUSTING

1) When the message return screen displays, input

a number with the function switch, and confirm
the number. After confirming the number, the
message of “Do you send Numeric Input?” ap-
pears.
F1: Decreases the input value by 1
F2: Increases the input value by 1
F3: Cancels the input and returns the screen to
“Service Menu” screen
F4: Enters the input value
2) When “Do you send Numeric Input?” is displayed,
input a number with the function switch, and con-
firm the number. The entered information is re-
turned to KOMTRAX base station
F3: Cancels the transmission and returns to
“Message Return” screen
F4: Enters the transmission
REMARK
• The message is different from that sent to the
operator in the operator mode.
• This message is only for the technician. Even
if a message is received, the message moni-
tor is not displayed in the same way as the
display in the operator mode.

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30 TESTING AND ADJUSTING METHOD FOR STARTING UP KOMTRAX TERMINAL

METHOD FOR STARTING UP KOMTRAX TERMINAL

Method for starting up komtrax terminal
Observe the following for using KOMTRAX.
1. KOMTRAX key person performs “Machine Registration” by using KOMTRAX client PC.
2. Perform “KOMTRAX Communication Inspection”.
• For operation procedures, see “Global KOMTRAX Web Reference Manual (For Key Person)”.
• Operating the KOMTRAX client PC requires the KOMTRAX key person authority of each distributor.
Therefore, consult the KOMTRAX key person before using it.

When KOMTRAX terminal is replaced

Observe the following when replacing KOMTRAX terminal and using it again.
1. Our technician provides a new terminal, and records the part number and serial number.
2. Our technician replaces the terminal, and perform “KOMTRAX Communication Inspection”. Our technician
notifies KOMTRAX key person of the completion of inspection work and new terminal information.
3. KOMTRAX key person performs “Terminal Replacement” by using KOMTRAX client PC.
4. KOMTRAX key person fills in required items on “Terminal Replacement Sheet”, and send it by email to
KOMTRAX support center via KOMTRAX administrator in the subsidiary.
• For details, see “Global KOMTRAX Web Reference Manual (For Key Person)”.
• Operating the KOMTRAX client PC requires the KOMTRAX key person authority of each distributor.
Therefore, consult the KOMTRAX key person before using it.

Machine side inspection for KOMTRAX Communication opening

• KOMTRAX Communication Inspection must be done to check whether normal communication is available
from the terminal when the KOMTRAX terminal is replaced or started up.
• By performing this inspection, KOMTRAX starts communication.
• GPS and data communication are checked during the radio station establishment. Accordingly, it is prefera-
ble to place the machine under the open sky where radio wave from the satellite is not blocked. The radio
station establishment may not be completed when the machine is placed indoor where radio wave from the
satellite is blocked.
1. Check the machine for KOMTRAX Communication Inspection
Observe the following when checking if KOMTRAX Communication Inspection is to be performed or not.
1) On “Service Menu” screen, use the function switch to
select “KOMTRAX Settings”.

PC45MR-5, PC55MR-5 30-155

METHOD FOR STARTING UP KOMTRAX TERMINAL 30 TESTING AND ADJUSTING

2) When the “KOMTRAX Settings” screen is displayed,

use the function switch to select “Terminal Status”.

3) On “Terminal Status” screen, check the state of “KOM-

TRAX Comm Inspection”.
REMARK
When the state of “KOMTRAX Communication In-
spection” shows “KOMTRAX Communication Not
Open”, perform step 2. When “Already Open” is dis-
played, there is no need of radio station establish-
ment.
2. KOMTRAX Communication Inspection
Observe the following when performing KOMTRAX Com-
munication Inspection.
1) On “Service Menu” screen, use the function switch to
select “KOMTRAX Settings”.

2) On “KOMTRAX Settings” screen, select “GPS & Com-

munication State” with the function switches.

3) After “GPS & Communication State” screen is dis-

played, press the function switch F8 to select following
switches (F8 + F1 → F2 → F3).

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30 TESTING AND ADJUSTING METHOD FOR STARTING UP KOMTRAX TERMINAL

4) After “Are you sure you want to inspect?” is displayed,

execute the inspection with the function switch.
F3: Returns the screen to “GPS & Communication
State” screen
F4: Executes KOMTRAX Communication Inspection.

5) The screen displays the state of KOMTRAX Commu-

nication inspection. Check on this screen that all item
are “OK”.
“Modem”: “OK” is displayed when communication area
is confirmed.
“GPS”: “OK” is displayed when it acquires GPS data.
“Transmission”: “OK” is displayed when it transmits
data correctly.
“Inspection State”: When all items of “Modem”, “GPS”,
and “Transmission” are “OK”, “OK” is displayed on
“Inspection State”.
• It takes 90 seconds to 15 minutes for all items to be “OK”.
• While waiting for all items to be “OK”, operation such as turning the starting switch to OFF position
or starting the engine will not be a problem.
If there is nothing abnormal, KOMTRAX Communication Inspection finishes automatically. Select
“KOMTRAX Settings” → “Terminal Status” of “Service Menu” to make sure that “Already Open” is
indicated for the item in “KOMTRAX Comm Inspection”.
• KOMTRAX Communication Inspection may not be completed when the machine is placed indoor
where radio wave from the satellite is blocked.
6) When all items are “OK”, “Inspection finished normal-
ly.” screen automatically displayed.
REMARK
• Press function switch F4. When “GPS & Commu-
nication State” appears, the KOMTRAX Communi-
cation Inspection for machine side has completed.
• Other than the above, perform step 3.
3. Troubleshooting when KOMTRAX Communication Inspec-
tion is finished unsuccessfully
• If any of 1) to 5) in step 2 is finished unsuccessfully,
perform inspection from 1) in step 2.
• If 6) in step 2 is finished unsuccessfully, following problems are suspected.

Troubleshooting when the failure occurs

Phenomenon Cause Required action
Something on the cab blocks off GPS sat-
Remove the obstacle on the cab.
GPS does not be- ellites acquisition.
come OK. GPS antenna cable is not connected to Check for the connection. If the connection is loose,
the KOMTRAX terminal, or they are loose. secure it.

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METHOD FOR STARTING UP KOMTRAX TERMINAL 30 TESTING AND ADJUSTING

Phenomenon Cause Required action

Check for state of in/out communication range with
The mobile phone is out of communication your mobile phone.
range. If it is out of communication range, move into com-
munication reception range and perform inspection.
Modem does not Communication antenna cable is not con-
become OK. Check for the connection. If the connection is loose,
nected to the KOMTRAX terminal, or they
secure it.
are loose.
KOMTRAX terminal is not connected to
Check for the connection. If the connection is loose,
machine side wiring harness, or they are
secure it.
loose.
4. After troubleshooting, perform 1) in step 2 again.
When the problems are not solved, contact your KOMTRAX support center.

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30 TESTING AND ADJUSTING METHOD FOR STARTING UP KOMTRAX TERMINAL

PC45MR-5, PC55MR-5 30-159

HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER 30 TESTING AND ADJUSTING

HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER

NOTICE
• Before connecting the wiring harness connector, be sure to completely remove sand, dust, water,
etc., inside the connector on the controller side.
• Disconnecting or connecting work of the connector between the engine controller and the engine
must be performed only when the starting switch and battery disconnect switch are in OFF position.
• Even when you perform troubleshooting, do not start the engine while a T-adapter is inserted into or
connected to the connector between the engine controller and engine.
REMARK
You may turn the starting switch to OFF or ON position but do not turn it to START position. (Do not
start the engine).

30-160 PC45MR-5, PC55MR-5

30 TESTING AND ADJUSTING TEST DIODES

TEST DIODES
Test the diode array (8-pin) and the single diode (2-pin) accord-
ing to the following procedure.
The continuity directions of the diode array are as shown in the
figure.
REMARK
The continuity direction of the single diode is indicated on the
surface of the diode.

METHOD FOR TESTING DIODE USING DIGITAL TESTER

1. Select the screen to the diode range to check the dis-
played values.
REMARK
When an ordinary circuit multimeter is used, the voltage of
the internal battery is indicated.
2. Apply the red (+) lead of the multimeter to the anode (P)
side of the diode and apply the black (-) lead to the cath-
ode (N) side, and check the indicated value.
3. Evaluate the condition of the diode by the indicated value.
Indicated value does not change: No continuity (defective)
Indicated value changes: Continuity (normal) (*)
In the case of a silicon diode, a value in the range between 460 to 600 mV is indicated.

METHOD FOR TESTING DIODE USING ANALOG TESTER

1. Selects the screen for resistance range.
2. Apply the red (+) lead of the multimeter to the anode (P) side of the diode and apply the black (-) lead to the
cathode (N) side, and check that the pointer moves.
3. Apply the red (+) lead of the multimeter to the cathode (N) side of the diode and apply the black (-) lead to
the anode (P) side, and check that the pointer moves.
4. Evaluate the condition of the diode by the movement of the pointer.
Result of movement of the pointer
Judgment
Step 2 Step 3
Normal (however, the movement of
the pointer (resistance) varies by type
Moves Does not move
of tester, or selection of measuring
range).
Moves Moves Defective (internal short circuit)
Does not move Does not move Defective (internal open circuit)

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40 TROUBLESHOOTING

PC45MR-5, PC55MR-5 40-1

CONTENTS 40 TROUBLESHOOTING

CONTENTS
ABBREVIATION LIST .................................................................................................................................... 40-6
RELATED INFORMATION ON TROUBLESHOOTING ................................................................................ 40-12
GENERAL TROUBLESHOOTING POINTS .......................................................................................... 40-12
SEQUENCE OF EVENTS IN TROUBLESHOOTING............................................................................ 40-13
CHECKS BEFORE TROUBLESHOOTING ........................................................................................... 40-15
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING ............................................................ 40-17
WALK-AROUND CHECK............................................................................................................... 40-17
TESTING IN ACCORDANCE WITH TESTING PROCEDURE.............................................................. 40-19
CHECK FUEL LEVEL AND TYPE.................................................................................................. 40-19
CHECK FUEL PREFILTER ............................................................................................................ 40-20
WATER SEPARATOR - CHECK / DRAIN WATER AND SEDIMENT.............................................. 40-22
CHECK MAIN FILTER ................................................................................................................... 40-23
CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN)............................................................. 40-26
CHECK COOLANT LEVEL (RESERVOIR TANK) .......................................................................... 40-27
CHECK CLOGGING OF AIR CLEANER........................................................................................ 40-28
CLEAN OUTER ELEMENT (SINGLE ELEMENT) .......................................................................... 40-29
CLEAN OUTER ELEMENT (DOUBLE ELEMENT) ........................................................................ 40-31
REPLACE SINGLE ELEMENT ...................................................................................................... 40-34
REPLACE DOUBLE ELEMENT ..................................................................................................... 40-36
CHECK HYDRAULIC OIL LEVEL .................................................................................................. 40-38
CHECK HYDRAULIC OIL STRAINER ........................................................................................... 40-42
CHECK HYDRAULIC FILTER ........................................................................................................ 40-43
CHECK OIL LEVEL IN FINAL DRIVE CASE.................................................................................. 40-45
BLEED AIR FROM FUEL SYSTEM .............................................................................................. 40-45
BLEED AIR FROM HYDRAULIC SYSTEM .................................................................................... 40-45
ELECTRICAL EQUIPMENT - CHECK METHOD ........................................................................... 40-45
ELECTRICAL SYSTEM TROUBLESHOOTING - PREPARATION ........................................................ 40-53
PROCEDURE FOR TESTING AND TROUBLESHOOTING ................................................................. 40-56
SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS .................................................... 40-59
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE........................................................... 40-63
CONNECTORS LIST AND LAYOUT..................................................................................................... 40-65
CONNECTOR CONTACT IDENTIFICATION (FOR 4D88E-7 ENGINE) ................................................ 40-81
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE .......................................................................... 40-85
FUSE LOCATION TABLE ..................................................................................................................... 40-91
FAILURE CODES TABLE ..................................................................................................................... 40-95
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) ............................................................40-105
FAILURE CODE [989L00] ....................................................................................................................40-105
FAILURE CODE [989M00] ...................................................................................................................40-106
FAILURE CODE [989N00] ...................................................................................................................40-107
FAILURE CODE [AQ20R1] ..................................................................................................................40-108
FAILURE CODE [B@BCNS] ................................................................................................................40-109
FAILURE CODE [D19JKZ] ...................................................................................................................40-110
FAILURE CODE [D811MC] ..................................................................................................................40-113
FAILURE CODE [D862KA]...................................................................................................................40-114
FAILURE CODE [D8ALKA] ..................................................................................................................40-115
FAILURE CODE [D8ALKB] ..................................................................................................................40-117
FAILURE CODE [D8AQKR] .................................................................................................................40-119
FAILURE CODE [DAF0KT] ..................................................................................................................40-121
FAILURE CODE [DAF0MB] .................................................................................................................40-122
FAILURE CODE [DAF0MC] .................................................................................................................40-123
FAILURE CODE [DAF3KK] ..................................................................................................................40-124
FAILURE CODE [DAF9KQ]..................................................................................................................40-126
FAILURE CODE [DAFGMC] ................................................................................................................40-127
FAILURE CODE [DAFLKA] ..................................................................................................................40-128
FAILURE CODE [DAFLKB] ..................................................................................................................40-130
FAILURE CODE [DAFQKR] .................................................................................................................40-132

40-2 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING CONTENTS

FAILURE CODE [DB2QKR] .................................................................................................................40-133

FAILURE CODE [DBH0MC].................................................................................................................40-137
FAILURE CODE [DBH2KK]..................................................................................................................40-138
FAILURE CODE [DBH5KP]..................................................................................................................40-141
FAILURE CODE [DBH5KP]..................................................................................................................40-143
FAILURE CODE [DBH9KQ] .................................................................................................................40-145
FAILURE CODE [DBHLKA]..................................................................................................................40-147
FAILURE CODE [DBHLKB]..................................................................................................................40-149
FAILURE CODE [DBHQKR].................................................................................................................40-151
FAILURE CODE [DDNRKA].................................................................................................................40-156
FAILURE CODE [DDNRKY].................................................................................................................40-158
FAILURE CODE [DDNS00]..................................................................................................................40-160
FAILURE CODE [DDWLKA].................................................................................................................40-162
FAILURE CODE [DDWLKB].................................................................................................................40-164
FAILURE CODE [DFB1KZ] ..................................................................................................................40-166
FAILURE CODE [DFB3L8]...................................................................................................................40-168
FAILURE CODE [DFB5KZ] ..................................................................................................................40-170
FAILURE CODE [DHS1MA] .................................................................................................................40-172
FAILURE CODE [DHS5MA] .................................................................................................................40-174
FAILURE CODE [DKULKA]..................................................................................................................40-176
FAILURE CODE [DKULKB]..................................................................................................................40-178
FAILURE CODE [DKULKY]..................................................................................................................40-180
FAILURE CODE [DV00KB] ..................................................................................................................40-182
FAILURE CODE [DV20KB] ..................................................................................................................40-183
FAILURE CODE [DW43KA] .................................................................................................................40-185
FAILURE CODE [DW43KB] .................................................................................................................40-187
FAILURE CODE [DW43KY] .................................................................................................................40-189
FAILURE CODE [DW4CKY].................................................................................................................40-190
FAILURE CODE [DXA8KA]..................................................................................................................40-192
FAILURE CODE [DXA8KB]..................................................................................................................40-194
FAILURE CODE [DXE7KA]..................................................................................................................40-196
FAILURE CODE [DXE7KB]..................................................................................................................40-198
FAILURE CODE [DXE7KY]..................................................................................................................40-200
FAILURE CODE [DXEAKA] .................................................................................................................40-202
FAILURE CODE [DXEAKB] .................................................................................................................40-204
FAILURE CODE [DXEAKY] .................................................................................................................40-206
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) ..................................................................40-208
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) .......................................................40-208
E-2 ENGINE DOES NOT START (FUEL FEED PUMP SYSTEM) .......................................................40-214
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK ...........................................................40-216
E-4 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTH-
ING...................................................................................................................................................40-218
E-5 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING
.........................................................................................................................................................40-221
E-6 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING ........................40-222
E-7 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING...............................40-223
E-8 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING....
.........................................................................................................................................................40-224
E-9 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING ...........40-225
E-10 FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM ..........................40-226
E-11 DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL LEVEL........................................40-228
E-12 ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR
MAXIMUM ........................................................................................................................................40-229
E-13 DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIFFERS FROM ACTUAL COOLANT
TEMPERATURE...............................................................................................................................40-230
E-14 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED ...............................40-231
E-15 FUNCTION SWITCH DOES NOT OPERATE ..............................................................................40-232
E-16 AUTO-DECELERATOR IS NOT OPERATED OR CANCELED WITH LEVER .............................40-233

PC45MR-5, PC55MR-5 40-3

CONTENTS 40 TROUBLESHOOTING

E-17 WHEN WORKING MODE IS CHANGED, SETTING OF ENGINE AND HYDRAULIC PUMP IS NOT
CHANGED .......................................................................................................................................40-234
E-18 WHEN TRAVEL SPEED SELECTION IS CHANGED, ACTUAL TRAVEL SPEED DOES NOT
CHANGE ..........................................................................................................................................40-235
E-19 ALARM BUZZER DOES NOT SOUND........................................................................................40-237
E-20 ALARM BUZZER CANNOT BE CANCELED ...............................................................................40-238
E-21 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION.....40-239
E-22 SERVICE MODE CANNOT BE SELECTED ................................................................................40-240
E-23 ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHANISM DO NOT MOVE .............40-241
E-24 ALL OF WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT LOCK.................40-243
E-25 ALARM DOES NOT SOUND DURING TRAVEL .........................................................................40-245
E-26 ALARM DOES NOT STOP SOUNDING WHILE MACHINE IS STOPPED...................................40-247
E-27 HORN DOES NOT SOUND.........................................................................................................40-248
E-28 HORN DOES NOT SOUND (FOR PROPORTIONAL LEVER SPEC)..........................................40-250
E-29 HORN DOES NOT STOP SOUNDING........................................................................................40-252
E-30 HORN DOES NOT STOP SOUNDING (FOR PROPORTIONAL LEVER SPEC) .........................40-254
E-31 WORKING LAMP OR TRAVEL LAMP DOES NOT LIGHT UP (CANOPY SPEC) .......................40-256
E-32 NONE OF WORKING LAMP, TRAVEL LAMP, OR ADDITIONAL LAMP DOES NOT LIGHT UP (CAB
SPEC) ..............................................................................................................................................40-260
E-33 WHEN WIPER SWITCH IS OPERATED, WINDSHIELD WIPER DOES NOT OPERATE............40-264
E-34 WHEN WINDOW WASHER SWITCH IS OPERATED, WINDOW WASHER DOES NOT OPERATE .....
.........................................................................................................................................................40-266
E-35 TRAVEL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION ........40-268
E-36 Swing or Arm IN IS NOT DISPLAYED NORMALLY IN MONITORING FUNCTION .....................40-269
E-37 Work Equipment IS NOT DISPLAYED NORMALLY IN MONITORING FUNCTION .....................40-270
E-38 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY ..........................................................40-272
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) ..............................40-273
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE)........................................40-273
H-1 ALL WORK EQUIPMENT, TRAVEL, SWING OR BLADE DO NOT OPERATE..............................40-274
H-2 ALL WORK EQUIPMENTS OR TRAVEL DOES NOT OPERATE..................................................40-275
H-3 TRAVEL OR BLADE DOES NOT OPERATE.................................................................................40-276
H-4 SWING OR BLADE DOES NOT OPERATE ..................................................................................40-277
H-5 ALL WORK EQUIPMENT, TRAVEL, SWING AND BLADE SPEED OR POWER IS LOW .............40-278
H-6 ALL WORK EQUIPMENT AND TRAVEL SPEED OR POWER IS LOW ........................................40-279
H-7 TRAVEL AND BLADE SPEED OR POWER IS LOW.....................................................................40-280
H-8 SWING AND BLADE SPEED OR POWER IS LOW ......................................................................40-281
H-9 FINE CONTROL PERFORMANCE OR RESPONSE IS POOR.....................................................40-282
H-10 UNUSUAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP .........................................40-283
H-11 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS..........................................................40-284
H-12 ALL WORK EQUIPMENTS SPEED OR POWER IS LOW ..........................................................40-286
H-13 ALL WORK EQUIPMENTS AND BLADE SPEED OR POWER IS LOW......................................40-287
H-14 BLADE DOES NOT OPERATE ...................................................................................................40-288
H-15 ALL WORK EQUIPMENTS DO NOT OPERATE .........................................................................40-289
H-16 ALL WORK EQUIPMENTS OR BLADE DO NOT OPERATE ......................................................40-290
H-17 SPEED OR POWER OF BOOM IS LOW ....................................................................................40-291
H-18 ARM SPEED OR POWER IS LOW .............................................................................................40-293
H-19 BUCKET SPEED OR POWER IS LOW.......................................................................................40-294
H-20 BLADE SPEED OR POWER IS LOW .........................................................................................40-295
H-21 BOOM SWING SPEED OR POWER IS LOW .............................................................................40-297
H-22 WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION ............................................40-298
H-23 HYDRAULIC DRIFT OF BOOM IS LARGE .................................................................................40-299
H-24 HYDRAULIC DRIFT OF ARM IS LARGE ....................................................................................40-300
H-25 HYDRAULIC DRIFT OF BUCKET IS LARGE..............................................................................40-301
H-26 HYDRAULIC DRIFT OF BLADE IS LARGE ................................................................................40-302
H-27 TIME LAG OF WORK EQUIPMENT IS LARGE ..........................................................................40-304
H-28 IN COMBINED OPERATION OF WORK EQUIPMENT, EQUIPMENT HAVING HEAVIER LOAD
MOVES SLOWER ............................................................................................................................40-305
H-29 MACHINE DOES NOT TRAVEL STRAIGHT ...............................................................................40-306

40-4 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING CONTENTS

H-30 MACHINE DOES NOT MOVE OFF STRAIGHT ..........................................................................40-308

H-31 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW......................................40-309
H-32 TRAVEL SPEED IS LOW ............................................................................................................40-311
H-33 BOTH SIDES OF CRAWLERS DO NOT MOVE..........................................................................40-313
H-34 ONE OF TRACKS DOES NOT RUN ...........................................................................................40-314
H-35 TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO SLOW OR FAST ...........40-316
H-36 UPPER STRUCTURE DOES NOT SWING BOTH TO THE RIGHT AND LEFT ..........................40-317
H-37 SWINGS ONLY IN ONE DIRECTION..........................................................................................40-319
H-38 SWING ACCELERATION OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND LEFT) ...
.........................................................................................................................................................40-321
H-39 SWING ACCELERATION PERFORMANCE IS POOR OR SWING SPEED IS SLOW IN ONLY ONE
DIRECTION......................................................................................................................................40-323
H-40 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (BOTH RIGHT
AND LEFT).......................................................................................................................................40-324
H-41 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (ONLY ONE DI-
RECTION EITHER RIGHT OR LEFT) ..............................................................................................40-325
H-42 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWINGING ......................................40-326
H-43 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS SWINGING.........40-327
H-44 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED)........40-328
H-45 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED) ....40-329
TROUBLESHOOTING OF ENGINE (S-MODE) ..........................................................................................40-330
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE)........................................40-330
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION...40-331
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT ..........................................................40-332
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT
DOES NOT START) .........................................................................................................................40-333
S-4 ENGINE STARTABILITY IS POOR................................................................................................40-334
S-5 ENGINE DOES NOT PICK UP SMOOTHLY .................................................................................40-336
S-6 ENGINE STOPS DURING OPERATION .......................................................................................40-338
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE .................................................................................40-339
S-8 ENGINE LACKS POWER..............................................................................................................40-340
S-9 KDPF GETS CLOGGED IN A SHORT TIME .................................................................................40-342
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE ...........................................................................40-343
S-11 OIL BECOMES CONTAMINATED QUICKLY ...............................................................................40-344
S-12 FUEL CONSUMPTION IS EXCESSIVE ......................................................................................40-345
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) ...40-346
S-14 OIL PRESSURE DROPS ............................................................................................................40-347
S-15 FUEL MIXES INTO ENGINE OIL.................................................................................................40-349
S-16 WATER MIXES INTO ENGINE OIL (MILKY) ...............................................................................40-350
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) .............................................40-351
S-18 UNUSUAL NOISE IS HEARD......................................................................................................40-352
S-19 VIBRATION IS EXCESSIVE ........................................................................................................40-353
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT..........................................................................40-354

PC45MR-5, PC55MR-5 40-5

ABBREVIATION LIST 40 TROUBLESHOOTING

40-6 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING ABBREVIATION LIST

Purpose of use (major ap-

PC45MR-5, PC55MR-5 40-7

ABBREVIATION LIST 40 TROUBLESHOOTING

Purpose of use (major ap-

Komatsu Catalyzed This is a filter that captures soot in exhaust gas.

40-8 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING ABBREVIATION LIST

Purpose of use (major ap-

PC45MR-5, PC55MR-5 40-9

ABBREVIATION LIST 40 TROUBLESHOOTING

Purpose of use (major ap-

*1: Code for applicable machine model

40-10 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING ABBREVIATION LIST

Abbreviation Actual word spelled out

S/T
Steering
STRG
SIG Signal
SOL Solenoid
STD Standard
OPT
Option
OP
PRESS Pressure
SPEC Specification
SW Switch
TEMP Temperature
T/C Torque Converter
T/M Transmission

PC45MR-5, PC55MR-5 40-11

GENERAL TROUBLESHOOTING POINTS 40 TROUBLESHOOTING

RELATED INFORMATION ON TROUBLESHOOTING

GENERAL TROUBLESHOOTING POINTS
k If you remove the radiator cap while the engine is still hot, hot coolant may spout out and can scald
you. Wait until the engine cools down.
k Take extreme care not to touch a hot portion or not to be wound in a turning portion.
k Before removing a plug or a cap of a portion where oil pressure, hydraulic pressure, or air pressure
is applied, release the internal pressure first, then connect the measuring tool securely.
k When disconnecting wiring, remove the key and turn the battery disconnect switch to OFF position.
k Park the machine on a level place and check the frame lock bar, chocks, parking brake, etc.
k When working in a group, make signs and allow only the persons concerned to approach the ma-
chine.
• Troubleshooting means to investigate the root cause of a failure, repair immediately, and prevent recur-
rence of the failure.
• One important thing when you perform troubleshooting is to understand the structure and operation.
• It is important to have an interview with the operator and set up an aim of failure cause for performing a
troubleshooting effectively.
• If you disassembly the machine hastily when it has a failure, you may disassemble unrelated portions and
may not be able to find the cause. As a result, the costs of the man-hours, parts, oil, or grease may in-
crease, and you may lose the confidence of the users and operators. Accordingly, sufficient advance check
and proper procedure are necessary for troubleshooting.
1. Ask users or operators the following questions.
1) Have any other problems occurred apart from the problem that has been reported?
2) Is there anything strange about the machine before the failure occurred?
3) Did the failure occur suddenly, or were there problems with the machine condition before this?
4) Under what conditions did the failure occur?
5) Had any repairs been performed before the failure? When were these repairs performed?
6) Has the same kind of failure occurred before?
2. Perform the following checks before troubleshooting.
1) Check the machine for a symptom of abnormality.
2) Perform the Check before starting items.
3) Check the other check items.
4) Check other maintenance matters which can be checked externally and are considered to be necessa-
ry.
3. Check the degree of the trouble by yourself and judge if it is a real failure or it is a problem of handling or
operation.
When reproducing the trouble phenomenon by operating the machine, do not perform check or measure-
ment that can increase the failure.
4. Use the results of the investigation and inspection to narrow down the probable causes of the failure, then
use the troubleshooting flow chart (matrix) to locate the failure exactly.
The basic troubleshooting procedure is as follows.
• Start from the simple points.
• Start from the most likely points.
• Investigate other related parts or information.
5. If the root cause is not corrected, a similar failure may occur again even if the apparent failure has been
repaired. Always find out the cause of a failure first and remove the root cause of each failure.

40-12 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING SEQUENCE OF EVENTS IN TROUBLESHOOTING

SEQUENCE OF EVENTS IN TROUBLESHOOTING

PC45MR-5, PC55MR-5 40-13

SEQUENCE OF EVENTS IN TROUBLESHOOTING 40 TROUBLESHOOTING

40-14 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING

CHECKS BEFORE TROUBLESHOOTING

Engine, lubricating oil, and coolant
No. Item Criteria Remedy
1 Check for unusual noise and smell - Repair
2 Check around engine for dirt - Remove
3 Check around engine for water leakage - Repair
4 Check around engine for oil leakage - Repair
5 Check fuel line for leakage - Repair
6 Check radiator for clogging - Remove
7 Check fuel level and type - Refill with oil
8 Check foreign material in fuel - Clean and drain
9 Check fuel prefilter - Replace
10 Check fuel main filter - Replace
11 Check of engine oil level (in oil pan) and type Between H and L Refilling with oil
12 Check of coolant level (in sub tank) Between H and L Refilling with coolant
Red piston is not pro-
jected into the transpar-
13 Check air cleaner for clogging Clean or replace
ent part of the dust indi-
cator.
14 Check around KDPF for dirt - Remove
15 Check around KDPF for gas leakage - Repair

Hydraulic and mechanical equipment

No. Item Criteria Remedy
1 Check for unusual noise and smell - Repair
2 Check for oil leakage - Repair
3 Check hydraulic oil level Between H and L Refilling with oil
4 Check hydraulic oil strainer - Clean and drain
5 Check hydraulic oil filter - Replace
6 Check oil level in final drive case - Refill with oil
7 Bleed air - Bleed air from cylinder

Electric equipment
No. Item Criteria Remedy
1 Check battery terminal for looseness and corrosion - Retighten or replace
Check battery disconnect switch terminal for looseness and
2 - Retighten or replace
corrosion
3 Check alternator terminal for looseness and corrosion - Retighten or replace
4 Check starting motor terminal for looseness and corrosion - Retighten or replace
5 Check battery voltage (with engine stopped) 10 to 15 V Charge or replace
6 Check battery electrolyte level Between H and L Refill or replace

PC45MR-5, PC55MR-5 40-15

CHECKS BEFORE TROUBLESHOOTING 40 TROUBLESHOOTING

No. Item Criteria Remedy

Check wiring harness for discoloration, burnt areas and
7 - Repair or replace
cover peeling
Check for coming off of wiring harness clamp and sagging
8 - Repair
of wiring harness
9 Check grounding - Repair
10 Check for loose connector and damaged lock - Repair or replace
11 Check connector pin for corrosion, bends and deformation - Repair or replace
12 Check connector for entering of water and foreign material - Dry, clean or replace
13 Check wiring harness for open or short circuit - Repair or replace
14 Check fuse for blowing out and corrosion - Replace
Check alternator voltage (when engine speed is medium or After few minutes of op-
15 Replace
higher) eration13.5 to 14.5 V
Check battery relay operation sound (when starting switch
16 - Replace
is turned to ON or OFF position)

Exterior
No. Item Criteria Remedy
1 Check undercarriage - Repair
2 Check handrails - Repair
3 Check mirrors - Clean or repair

Interior
No. Item Criteria Remedy
1 Check gauges and monitors - Clean or replace
2 Check seat belt - Replace

40-16 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING INSPECTION PROCEDURE BEFORE TROUBLESHOOTING

INSPECTION PROCEDURE BEFORE TROUBLESHOOTING

WALK-AROUND CHECK
Before starting the engine, look around and under the machine to check for any loose nuts or bolts, leakages of
oil, fuel, or coolant, and check the condition of the work equipment and hydraulic system.
Check the connectors for looseness, wiring harnesses for play, and accumulation of dust in places that reach
high temperatures.
k Accumulated combustibles and fuel or oil leakages around hot engine parts such as engine, after-
treatment devices, etc. may cause a machine fire. Be sure to check thoroughly and repair any fail-
ures.
• Check of unusual noise and smell
Check for unusual noise or smell.
If the machine is operated under the unusual noise or smell, the cause of it may damage the machine, so
stop the operation immediately once you recognize it.
• Check around engine and removal of dirt
Check and remove any accumulated dirt around the engine and any combustibles (dead leaves, twigs, etc.)
on hot engine parts such as the aftertreatment devices, etc.
• Check around engine for water leakage
• Check around engine for oil leakage
Check for oil leakage from engine and coolant leakage from cooling system. If any abnormality is found,
repair it.
• Check of fuel line for leakage
Check for fuel leakage, check hoses and pipes for damage. If any abnormality is found, repair it.
• Check of radiator and removal of dirt
Check if there is any accumulated dirt and any combustibles (dead leaves, twigs, etc.) around the radiator.
If any, remove them.
For removal of foreign article in the radiator, see “Operation and Maintenance Manual”.
• Check around the aftertreatment devices and removal of dirt
Check if there is any accumulated dirt and any combustibles (dead leaves, twigs, etc.) around the after-
treatment devices. If any, remove them.
• Check around the aftertreatment device for gas leakage
Check the pipe the KDPF, and also the aftertreatment devices connection for leakage of exhaust gas (or
sticking of soot, etc.). If any abnormality is found, repair it.
• Check of work equipment, cylinders, linkage and hoses for breakage, wear and clearance
Check the work equipment, cylinders, linkage, and hoses for breakage, wear, and clearance. If any abnor-
mality is found, repair it.
• Check of hydraulic equipment, hydraulic tank, hoses, and joints for oil leakage
Check for oil leaks. If any abnormality is found, repair it.
• Air bleeding
For the bleeding air from the fuel system, see TESTING AND ADJUSTING, “BLEED AIR FROM FUEL
SYSTEM”.
For the bleeding air from the hydraulic system, see TESTING AND ADJUSTING, “BLEED AIR FROM HY-
DRAULIC CIRCUIT”.
• Check the undercarriage (track, sprocket, idler, guard) for damage, wear, loose bolts, or leakage of oil from
rollers
If any abnormality is found, repair it.
• Check of handrails for abnormality and looseness of bolts
If any abnormality is found, repair it and tighten any loose bolts.
• Check and clean of rearview mirrors
Check rearview mirror for abnormality. If any, repair it.
Clean the mirror surface and adjust the mirror angle so that the rear of the machine can be seen from the
operator's seat.

PC45MR-5, PC55MR-5 40-17

INSPECTION PROCEDURE BEFORE TROUBLESHOOTING 40 TROUBLESHOOTING

• Check of gauges and monitors for abnormality

Check gauges and monitors in the operator's cab for abnormality. If any abnormality is found, replace it with
a new one.
Clean up the surfaces.
• Check of seat belt and mounting hardware
Check the hook, the lock, and hook mounting part for damage. If any abnormality is found, repair it.

40-18 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING TESTING IN ACCORDANCE WITH TESTING PROCEDURE

TESTING IN ACCORDANCE WITH TESTING PROCEDURE

CHECK FUEL LEVEL AND TYPE
k Fuel is highly flammable and dangerous. Keep open flame away.
k When adding fuel, be careful not to overflow it.
k Wipe off any spilled fuel. If fuel spills over soil or sand, remove all the fuel and soil or sand together.
1. Turn the engine starting switch to ON position and check
the fuel level with the fuel gauge (2) on the monitor panel.
After checking, turn the switch back to OFF position.

2. Open dirt cover (3).

Open dirt cover (3) fully and it will be secured by cover
support lever (4).

3. If the fuel level is low, open fuel filler cap (F) of the fuel
tank and add fuel through the fuel filler port to the neces-
sary level, referring to the position of float gauge (G).

4. Tighten the cap of oil filler port (F) securely.

REMARK
If breather hole (5) in the oil filler cap is clogged, the pres-
sure in the tank decreases and fuel may not be supplied.
To prevent this, clean the breather hole.

PC45MR-5, PC55MR-5 40-19

TESTING IN ACCORDANCE WITH TESTING PROCEDURE 40 TROUBLESHOOTING

CHECK FUEL PREFILTER

1. Set the machine in the posture shown in the figure.
1) Start the engine.

2) Set the lock lever to FREE position (F).

3) Operate the work equipment control lever slowly to
right and left to swing the upper structure so that the
fuel prefilter comes between the tracks
4) Operate the work equipment control levers, and lower
the work equipment to the ground.

5) Set the lock lever to LOCK position (L).

6) Stop the engine.

2. Pull engine rear cover (1) toward you to open it.

Open engine rear cover (1) fully and it is secured by rod
(2).

3. Pull cooling cover (3) toward you to open it.

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40 TROUBLESHOOTING TESTING IN ACCORDANCE WITH TESTING PROCEDURE

4. Turn rod (4) to LOCK position (L), and fix cooling cover (3)
with the rod.

5. Loosen bolts (5) and remove undercover (6).

6. Place a container under the fuel prefilter to receive the
fuel.

7. Turn handle (7) to CLOSE position (S), and loosen drain

plug (8).
8. Drain the water until red ring (9) contacts to the bottom of
transparent cup (10).
9. Tighten drain plug (8).

10. Turn transparent cup (10) counterclockwise to remove it.

Remove transparent cup (10) without spilling the fuel.
If the fuel spills, wipe it off with cloth thoroughly.
Be careful not to lose red ring (9) in transparent cup (10).

11. Remove element (11) from top of the fuel prefilter, and re-
place it with a new element.
12. Check the condition of O-ring (12) installed to transparent
cup (10).
Replace the O-ring with a new one if needed.
13. Clean the inside of transparent cup (10) with diesel fuel or
flushing oil.
14. Install the element (11) and O-ring (12) to transparent cup
(10).
15. Insert red ring (9) into transparent cup (10) and fill it with
fuel.

PC45MR-5, PC55MR-5 40-21

TESTING IN ACCORDANCE WITH TESTING PROCEDURE 40 TROUBLESHOOTING

16. Install transparent cup (10) to bottom of fuel prefilter.

3 Tightening torque:
27 to 33 Nm {2.8 to 3.4 kgm}

17. Turn handle (7) to OPEN position (O).

18. Install undercover (6) with bolts (5).
19. After replacement of the element is completed, bleed air
from the fuel circuit.
20. Set rod (4) to FREE position (F), and close cooling cover
(3).
21. Close engine rear cover (1).

WATER SEPARATOR - CHECK / DRAIN WATER AND SEDIMENT

1. Pull engine rear cover (1) toward you to open it.
Open engine rear cover (1) fully and it is secured by rod
(2).

2. Pull cooling cover (3) toward you to open it.

3. Set rod (4) to LOCK position (L), and fix cooling cover (3)
with the rod.

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40 TROUBLESHOOTING TESTING IN ACCORDANCE WITH TESTING PROCEDURE

4. Check for water and sediment.

If red ring (5) of water separator sinks at the bottom of
transparent cup (6), water is not mixed.
If red ring (5) floats, water enters up to under red ring (5).
Drain the mixed water according to the following proce-
dure.

1) Set the machine in the posture shown in the figure.

1] Start the engine.
2] Set the lock lever to FREE position.
3] Operate the work equipment control lever slowly
to right and left to swing the upper structure so
that the fuel prefilter comes between the tracks
4] Operate the work equipment control levers, and
lower the work equipment to the ground.
5] Set the lock lever to LOCK position.
6] Stop the engine.
2) Place a container under the fuel prefilter to receive the fuel.
3) Turn handle (7) to CLOSE position (S), and loosen
drain plug (8).
4) Drain the water until red ring (5) contacts to the bot-
tom of transparent cup (6).

5) Tighten drain plug (8), and turn handle (7) to OPEN

position (O).

5. Set rod (4) to FREE position (F), and close cooling cover (3).
6. Close engine rear cover (1).

CHECK MAIN FILTER

k Immediately after the engine is stopped, its parts and oil are still very hot, and may cause burn in-
jury. Accordingly, wait until all parts have cooled down before starting the work.
k High pressure is generated inside the engine fuel piping system when the engine is running. Stop
the engine and wait at least 30 seconds until the inner pressure is released and then replace the fil-
ter.
k Keep open flame away.

PC45MR-5, PC55MR-5 40-23

TESTING IN ACCORDANCE WITH TESTING PROCEDURE 40 TROUBLESHOOTING

NOTICE
• Komatsu genuine fuel filter cartridges adopt a special filter with high-efficiency filtering properties.
Komatsu recommends using Komatsu genuine parts when replacing.
• The common rail fuel injection system used on this machine consists of more precise parts than
those in the conventional injection pump and nozzles. If any cartridge other than a Komatsu genuine
fuel filter cartridge is used, foreign materials may enter and problem may occur in the injection sys-
tem. Do not use substitute parts.
• During testing or maintenance of the fuel system, take extreme care that any foreign material does
not enter the fuel system. If any dust or other material sticks to any part, wash the part thoroughly
with clean fuel.
• Prepare a container to receive drained fuel.
• Prepare a filter wrench.
1. Pull engine rear cover (1) toward you to open it.
Open engine rear cover (1) fully and it is secured by rod
(2).

2. Pull cooling cover (3) toward you to open it.

3. Turn rod (4) to LOCK position (L), and fix cooling cover (3)
with the rod.

4. Turn handle (6) of fuel prefilter (5) to CLOSE position (S).

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40 TROUBLESHOOTING TESTING IN ACCORDANCE WITH TESTING PROCEDURE

5. Place a container under the fuel filter to receive the fuel.

6. Turn fuel filter cartridge (7) counterclockwise by using the

filter wrench, and remove it.
After removing fuel filter cartridge (7), fuel drips down from
the fuel filter head.
In order to prevent the fuel from flowing out, be sure not to
leave the machine without fuel filter cartridge (7).
7. Clean the mounting face of the fuel filter cartridge.
Do not fill the new fuel filter cartridge with fuel.

8. Remove cap (B) at the center, and install the fuel filter car-
tridge to the mounting face of fuel filter cartridge.
When installing it, apply a thin film of oil to the packing sur-
face, contact it to the sealing surface of filter cartridge (7),
and then tighten it 1/4 to 1/2 turn.
If the fuel filter cartridge is tightened too far, the packing
will be damaged and this will lead to leakage of fuel. If it is
tightened too loose, fuel will also leak from the packing, so
always tighten to the specified angle.
When tightening with a filter wrench, be extremely careful
not to dent or damage the filter.
9. Turn handle (6) of fuel prefilter (5) to OPEN position (O).

10. After completing the replacement of the fuel filter cartridge, bleed air according to the following procedure.
1) Fill up the fuel tank with fuel to the level where the float is at the highest position.

PC45MR-5, PC55MR-5 40-25

TESTING IN ACCORDANCE WITH TESTING PROCEDURE 40 TROUBLESHOOTING

2) Turn the starting switch to ON position (B).

3) 10 to 15 seconds later, return it to OFF position (A).

The air is bled automatically with automatic air bleed-
ing device.
REMARK
When the engine runs out of fuel, use the same procedure
to bleed the air.
11. After replacing the fuel filter cartridge, start the engine and
run it at low idle for 10 minutes.
12. Check the filter seal surface and the mounting face of the
transparent cup for fuel leakage.
If the fuel leaks, check according to the following procedure.
1) Check the fastening condition of the fuel filter cartridge.
2) If the fuel leaks, remove the fuel filter cartridge in step 4 to 6.
3) Check the packing surface for damage and pinching of foreign material.
If it has damage or pinching of foreign material, replace the fuel filter cartridge with a new one.
4) Install the fuel filter cartridge in step 6 to 10.
5) Check the filter seal surface and the mounting face of the transparent cup for fuel leakage, and if the
fuel leaks, heck again.
13. Set rod (4) to FREE position (F), and close cooling cover (3).
14. Close engine rear cover (1).

CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN)

k Immediately after the engine is stopped, its parts and oil are still very hot, and may cause burn injury.
Accordingly, wait until all parts have cooled down before starting the work.
REMARK
• When checking the oil level after the engine has been operated, wait at least 15 minutes after stopping the
engine.
• If the machine is inclining, make it level before checking.
1. Pull engine rear cover (1) toward you to open it.
Open engine rear cover (1) fully and it is secured by rod
(2).

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40 TROUBLESHOOTING TESTING IN ACCORDANCE WITH TESTING PROCEDURE

2. Pull out dipstick (G) and wipe the oil off with a cloth.
3. Fully insert dipstick (G) into the dipstick pipe, then remove
it.

4. Check if the oil is sticking up to between marks H and L on dipstick (G).

It is appropriate if the oil level is between marks H and L.
If the oil level is below mark L, add oil through oil filler port
(F).
If the oil level is below mark L, add oil through oil filler port
(F).
5. If the oil level is higher than mark H, decrease it to a prop-
er level according to the following procedure.

1) Drain excess engine oil through drain plug (P).

2) Check the oil level again.
6. If the oil level is proper, tighten the oil filler cap securely.
7. Close engine rear cover (1).

CHECK COOLANT LEVEL (RESERVOIR TANK)

k The radiator cap does not need to be opened for standard checks. When checking the coolant level,
check it in reservoir tank when the engine is cooled down.
k Immediately after the engine is stopped, the coolant is still very hot and the pressure is accumulated
in the radiator.
If the cap is opened under these conditions, you may be scalded. If you need to remove the radiator
cap, wait for the temperature to drop before you do. Then turn the cap slowly to release the pressure
and remove it with care.
1. Pull engine rear cover (1) toward you to open it.
Open engine rear cover (1) fully and it is secured by rod
(2).

PC45MR-5, PC55MR-5 40-27

TESTING IN ACCORDANCE WITH TESTING PROCEDURE 40 TROUBLESHOOTING

2. Pull cooling cover (3) toward you to open it.

3. Move rod (4) to LOCK position (L), and secure cooling

cover (3) with the rod.

4. Check the coolant level in reservoir tank (5).

If the coolant level is within FULL - LOW range when the
engine is cooled down, it is appropriate.
If the coolant level is below LOW, add coolant to FULL lev-
el through the filler port of reservoir tank (5).
REMARK
• If the reservoir tank is empty, coolant probably leaks. If
any abnormality is found after check, repair it immedi-
ately. If no abnormality is found, check the level of the
coolant in the radiator. If it is low, add coolant to the ra-
diator and then to the reservoir tank.
• If reservoir tank (1) is dirty and it is difficult to check the
coolant level, clean it.
5. Tighten the water filler cap of reservoir tank (5) securely.
6. Move rod (4) to FREE position (F), and close cooling cover
(3).
7. Close engine rear cover (1).

CHECK CLOGGING OF AIR CLEANER

k When using compressed air for cleaning, put on personal protective items such as protective eye-
glasses, gloves, dust mask, etc. to protect yourself from dirt that will fly out.
k When removing the outer element from the air cleaner body, do not forcibly pull it out, otherwise it
can be dangerous.
k When working in high places or on poor footing, be careful not to fall because of the reaction when
pulling out the outer element.

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40 TROUBLESHOOTING TESTING IN ACCORDANCE WITH TESTING PROCEDURE

Open the engine hood, and check if the red piston is protruding
into the transparent part of dust indicator (1). If it is protruding,
clean the air cleaner element.
REMARK
• Do not clean the element before the red piston is projected
into the transparent part of dust indicator (1).
• If the element is cleaned frequently before the red piston is
projected, the air cleaner will not deliver the optimum per-
formance, and the cleaning effect will decrease.

CLEAN OUTER ELEMENT (SINGLE ELEMENT)

1. Pull engine rear cover (1) toward you to open it.
Open engine rear cover (1) fully and it is secured by rod
(2).

NOTICE
Do not clean the outer element before the red piston is
projected into the transparent part of dust indicator (3).
If the outer element is cleaned frequently before the red
piston is projected, the air cleaner will not deliver the opti-
mum performance, and the efficiency of filtration will de-
crease.
2. Check if the red piston is projected into the transparent
part of dust indicator (3).
If the red piston is projected, clean the air cleaner outer el-
ement.
3. Release hooks (4) and remove cover (5).

4. Hold outer element (6), rock it lightly up and down and to

the right and left, and pull it out while turning it clockwise
and counterclockwise.
5. After removing outer element (6), cover the air connector
side at the bottom of air cleaner body (7) with a clean cloth
or tape to prevent dirt or dust from entering.
6. Clean dust sticking inside air cleaner body (7) and on cov-
er (5) by using a clean cloth or brush.
7. If any dust is attached to vacuator valve (8) installed to
cover (5), remove it.

PC45MR-5, PC55MR-5 40-29

TESTING IN ACCORDANCE WITH TESTING PROCEDURE 40 TROUBLESHOOTING

8. When outer element (6) has been cleaned 5 times or used for 1 year, replace it.
9. Blow dry compressed air (max. 0.2 MPa {max.
2.1 kg/cm2} ) from the inside of outer element (6) along the
pleats.
10. Blow along the pleats from the outside, then blow again
from the inside.

11. After cleaning, illuminate the inside of the element with an

electric bulb to check.
If any holes or thin places are found, replace the outer ele-
ment with a new one.
12. Remove the cover of cloth or tape attached to the air con-
nector side at the bottom of air cleaner body (7).

NOTICE
• Do not use the outer element with damaged pleats or a damaged gasket or seal.
• If the outer element and O-ring are cleaned and used again after they are used for more than 1 year,
it will cause problems. Do not use them again.
13. Check the seal of cleaned or new outer element (6) for adhesion of dusts and oil.
If there is adhesion of dusts and oil, wipe them off.
NOTICE
• Be sure to install the air cleaner element facing in the
correct direction. Install so that the bottom of the air
cleaner element (a) (face where no hole is drilled)
comes to cover (5) end.
If it is installed in wrong direction, it may cause break-
age of the air cleaner element or serious damage to the
engine.
• When inserting the element into the body, if the rubber
at the tip is swollen or the outer element is not pushed
in straight, and cover (5) is installed by force with hook
(4), there is a danger that hook (4) and air cleaner body
may be damaged, so be careful when installing.
14. Push outer element (6) straight into air cleaner body (7) with your hand.
Hold outer element (6), and rock it lightly up and down and to the right and left while pushing it in, the ele-
ment can be inserted easily.
15. Install cover (5).
Install cover (5) as follows.

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40 TROUBLESHOOTING TESTING IN ACCORDANCE WITH TESTING PROCEDURE

1) Align the mark on cover (5) with the mark on air clean-
er body (7).

2) Lock the tip of hook (4) on the protrusion of air cleaner

body (7).

3) Check that TOP mark arrow (A) on cover (5) is point-

ing upward.
4) When cover (5) is installed, check that the clearance
between air cleaner body (7) and cover (5) is not too
large.
If the clearance is too large, remove cover (5), and
then install it again.

16. Press the button of dust indicator (3) and return the red
piston.
NOTICE
Replace the outer element when the dust indicator in-
dicates red soon after cleaning the outer element,
even though it has not been cleaned 5 times yet.

CLEAN OUTER ELEMENT (DOUBLE ELEMENT)

1. Pull engine rear cover (1) toward you to open it.
Open engine rear cover (1) fully and it is secured by rod
(2).

PC45MR-5, PC55MR-5 40-31

TESTING IN ACCORDANCE WITH TESTING PROCEDURE 40 TROUBLESHOOTING

4. Hold outer element (6), rock it lightly up and down and to

the right and left, and pull it out while turning it clockwise
and counterclockwise.
5. When outer element (6) is removed, check that inner ele-
ment (9) does not come off or incline.
If it is at an angle, push it straight to the bottom with your
hand.
6. After removing outer element (6), cover the inner element
(9) with a clean cloth or tape to prevent dirt or dust from
entering.
7. Clean dust sticking inside air cleaner body (7) and on cover (5) by using a clean cloth or brush.
8. If any dust is attached to vacuator valve (8) installed to cover (5), remove it.
9. When outer element (6) has been cleaned 5 times or used for 1 year, replace it.
10. Blow dry compressed air (max. 0.2 MPa {max.
2.1 kg/cm2} ) from the inside of outer element (6) along the
pleats.
11. Blow along the pleats from the outside, then blow again
from the inside.

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40 TROUBLESHOOTING TESTING IN ACCORDANCE WITH TESTING PROCEDURE

12. After cleaning, illuminate the inside of the element with an

electric bulb to check.
If any holes or thin places are found, replace the outer ele-
ment with a new one.
13. Remove the cover of cloth or tape attached to inner ele-
ment (9).

NOTICE
• Do not use the outer element with damaged pleats or a damaged gasket or seal.
• If the outer element and O-ring are cleaned and used again after they are used for more than 1 year,
it will cause problems. Do not use them again.
14. Check the seal of cleaned or new outer element (6) for adhesion of dusts and oil.
If there is adhesion of dusts and oil, wipe them off.
NOTICE
• Be sure to install the air cleaner element facing in the
correct direction. Install so that the bottoms (a) and (b)
of the air cleaner element (face where no hole is drilled)
come to cover (5) end.
If it is installed in wrong direction, it may cause break-
age of the air cleaner element or serious damage to the
engine.
• When inserting the element into the body, if the rubber
at the tip is swollen or the outer element is not pushed
in straight, and cover (5) is installed by force with hook
(4), there is a danger that hook (4) and air cleaner body
may be damaged, so be careful when installing.
15. Push outer element (6) straight into air cleaner body (7) with your hand.
Hold outer element (6), and rock it lightly up and down and to the right and left while pushing it in, the ele-
ment can be inserted easily.
16. Install cover (5).
1) Align the mark on cover (5) with the mark on air clean-
er body (7).

PC45MR-5, PC55MR-5 40-33

TESTING IN ACCORDANCE WITH TESTING PROCEDURE 40 TROUBLESHOOTING

2) Lock the tip of hook (4) on the protrusion of air cleaner

body (7).

3) Check that TOP mark arrow (A) on cover (5) is point-

17. Press the button of dust indicator (3) and return the red
piston.
NOTICE
Replace both inner and outer elements when the dust
indicator indicates red soon after cleaning the outer el-
ement even though it has not been cleaned 5 times
yet.

REPLACE SINGLE ELEMENT

1. Pull engine rear cover (1) toward you to open it.
Open engine rear cover (1) fully and it is secured by rod
(2).

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40 TROUBLESHOOTING TESTING IN ACCORDANCE WITH TESTING PROCEDURE

3. Release hooks (4) and remove cover (5).

4. Hold outer element (6), rock it lightly up and down and to

the right and left, and pull it out while turning it clockwise
and counterclockwise.
5. Clean dust sticking inside air cleaner body (7) and on cov-
er (5) by using a clean cloth or brush.
6. If any dust is attached to vacuator valve (8) installed to
cover (5), remove it.

NOTICE
• The sealing portion of the improper part lacks precision, and allows the entry of dust, which leads to
damage of the engine. Do not use such improper part.
• Be sure to install the air cleaner element facing in the correct direction.
Install so that the bottom of the air cleaner element (a) (face where no hole is drilled) comes to cover
(5) end.
If it is installed in wrong direction, it may cause breakage of the air cleaner element or serious dam-
age to the engine.
• When inserting the element into the body, if the rubber at the tip is swollen or the outer element is
not pushed in straight, and cover (5) is installed by force with hook (4), there is a danger that hook
(4) and air cleaner body may be damaged, so be careful when installing.
7. Push the new outer element in straight with your hand to air cleaner body (7).
Hold the new outer element, and rock it lightly up and down and to the right and left while pushing it in, the
element can be inserted easily.
8. Install cover (5).
1) Align the mark on cover (5) with the mark on air clean-
er body (7).

PC45MR-5, PC55MR-5 40-35

TESTING IN ACCORDANCE WITH TESTING PROCEDURE 40 TROUBLESHOOTING

2) Lock the tip of hook (4) on the protrusion of air cleaner

body (7).

3) Check that TOP mark arrow (A) on cover (5) is point-

9. Press the button of dust indicator (3) and return the red
piston.

REPLACE DOUBLE ELEMENT

1. Pull engine rear cover (1) toward you to open it.
Open engine rear cover (1) fully and it is secured by rod
(2).

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40 TROUBLESHOOTING TESTING IN ACCORDANCE WITH TESTING PROCEDURE

3. Release hooks (4) and remove cover (5).

4. Hold outer element (6), rock it lightly up and down and to

the right and left, and pull it out while turning it clockwise
and counterclockwise.
Do not remove inner element (9) at this time.
5. When outer element (6) is removed, check that the inner
element does not come out of position and is not at an an-
gle.
If it is at an angle, push it straight to the bottom with your
hand.
6. Clean dust sticking inside air cleaner body (7) and on cov-
er (5) by using a clean cloth or brush.
7. If any dust is attached to vacuator valve (8) installed to cover (5), remove it.
NOTICE
• Do not clean and reuse the inner element.
When replacing the outer element, replace the inner element with a new one at the same time.
• If the outer element and cover are installed while the inner element is not installed properly, the outer
element may be damaged.
• The sealing portion of the improper part lacks precision, and allows the entry of dust, which leads to
damage of the engine. Do not use such improper part.
• Be sure to install the air cleaner element facing in the correct direction.
Install so that the bottom of the air cleaner element (a) (face where no hole is drilled) comes to cover
(5) end.
If it is installed in wrong direction, it may cause breakage of the air cleaner element or serious dam-
age to the engine.
• When inserting the element into the body, if the rubber at the tip is swollen or the outer element is
not pushed in straight, and cover (5) is installed by force with hook (4), there is a danger that hook
(4) and air cleaner body may be damaged, so be careful when installing.
8. Remove inner element (9), and then quickly install the new inner element.
Install the inner element securely so that it does not move.
9. Push the new outer element in straight with your hand to air cleaner body (7).
Hold the outer element, and rock it lightly up and down and to the right and left while pushing it in, the ele-
ment can be inserted easily.

PC45MR-5, PC55MR-5 40-37

TESTING IN ACCORDANCE WITH TESTING PROCEDURE 40 TROUBLESHOOTING

10. Install cover (5).

1) Align the mark on cover (5) with the mark on air clean-
er body (7).

2) Lock the tip of hook (4) on the protrusion of air cleaner

body (7).

3) Check that TOP mark arrow (A) on cover (5) is point-

11. Press the button of dust indicator (3) and return the red
piston.

CHECK HYDRAULIC OIL LEVEL

k Immediately after the engine is stopped, its parts and oil are still very hot, and may cause burn in-
jury. Accordingly, wait until all parts have cooled down before starting the work.
k When removing the oil filler cap, the oil may spout out. Turn it slowly to release the internal pres-
sure, then remove it.

40-38 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING TESTING IN ACCORDANCE WITH TESTING PROCEDURE

1. Set the machine in the posture shown in the figure.

If it is not set in the posture shown in the figure, set it ac-
cording to the following procedure.
1) Start the engine.

2) Set the lock lever to FREE position (F).

3) Operate the blade control lever to lower the blade to
the ground.
4) Operate the work equipment control levers, and re-
tract arm cylinder and bucket cylinder to their stroke
end (maximum reach posture of arm and bucket).
5) Operate the boom swing control pedal to swing the
boom to the center position.
6) Operate the work equipment control lever slowly to the
boom LOWER direction, and lower the boom and
make tooth contact to the ground.
7) Set the lock lever to LOCK position (L).
8) Stop the engine.

2. Pull engine rear cover (1) toward you to open it.

Open engine rear cover (1) fully and it is secured by rod
(2).

3. Pull cooling cover (3) toward you to open it.

PC45MR-5, PC55MR-5 40-39

TESTING IN ACCORDANCE WITH TESTING PROCEDURE 40 TROUBLESHOOTING

4. Set rod (4) to LOCK position (L), and fix cooling cover (3)
with the rod.

5. Check the oil level through sight gauge (G).

It is appropriate if the oil level is between H and L.

If the oil level is below level L, the hydraulic oil is insuffi-
cient.
If the hydraulic oil is insufficient, add oil according to the
following procedure.

1) Open dirt cover (5).

Open dirt cover (5) fully and it will be secured by cover
support lever (6).

2) Loosen bolt (7) of the hydraulic tank, move plate (8)

on oil filler port (F), turn the cap of oil filler port (F)
slowly to remove it, and release the internal pressure.

3) Add hydraulic oil through oil filler port (F) until the oil level comes between levels H and L of sight
gauge (G).

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40 TROUBLESHOOTING TESTING IN ACCORDANCE WITH TESTING PROCEDURE

NOTICE
Do not add oil above H line.
It may damage the oil circuit and cause the oil to
spurt out.
If oil has been added exceeding level H, swing the
upper structure until drain plug (P) under the hy-
draulic tank comes between the right and left
tracks and stop the engine. Wait for the hydraulic
oil to cool down sufficiently, then drain the excess
oil through drain plug (P).
REMARK
The oil level vary with the oil temperature. Accordingly,
use the following as a guide for check:
Before starting the operation: Around L level
Oil temperature: 10 to 30 °C {50 to 86 °F}
In normal operation: Around H Level
Oil temperature: 50 to 80 °C {122 to 176 °F}
4) Start the engine.
5) Set the lock lever to FREE position (F).

6) Operate the work equipment control levers, and ex-

tend the boom cylinder, bucket cylinder, and arm cylin-
der to their stroke end.
Set the work equipment in the posture shown in the
figure.

7) Set the lock lever securely to LOCK position (L).

8) Stop the engine.
9) Tighten the cap of oil filler port (F) on the hydraulic
tank securely.
REMARK
By doing so, the hydraulic tank is pressurized.
NOTICE
If the hydraulic tank is not pressurized, air is
sucked in the pump and it affects the components
badly.
10) Return plate (8) on oil filler port (F) of the hydraulic tank to its original position, and fix it with bolt (7).

PC45MR-5, PC55MR-5 40-41

TESTING IN ACCORDANCE WITH TESTING PROCEDURE 40 TROUBLESHOOTING

11) Close dirt cover (6).

6. Set rod (4) to FREE position (F), and close cooling cover (3).
7. Close engine rear cover (1).

CHECK HYDRAULIC OIL STRAINER

k Immediately after the engine is stopped, its parts and oil are still very hot, and may cause burn in-
jury. Accordingly, wait until all parts have cooled down before starting the work.
k When removing the oil filler cap, the oil may spout out. Turn it slowly to release the internal pres-
sure, then remove it.
1. Open dirt cover (1).
Open dirt cover (1) fully and it will be secured by cover
support lever (2).

2. Loosen bolt (3) of the hydraulic tank, move plate (4) on oil
filler port (F), turn the cap of oil filler port (F) slowly to re-
move it, and release the internal pressure.

3. Loosen bolts (5) at the bottom of hydraulic tank, and re-

move undercover (6).

40-42 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING TESTING IN ACCORDANCE WITH TESTING PROCEDURE

4. Loosen hose clamp (7) and remove hose (8).

5. Loosen bolts (9) and remove tube (10).
6. Remove O-ring (11) and strainer (12) from tube (10), re-
move dirt, etc. stuck to the tube, and then wash it in clean
diesel fuel or flushing oil.
Replace O-ring (11) with a new O-ring.
If strainer (12) is damaged, replace it with a new strainer.
7. Fix strainer (12) with bolt (9).
8. Install hose (8) and fix it with hose clamp (7).
9. Install undercover (6) with bolts (5) to the bottom of the hy-
draulic tank.
10. Tighten the cap of oil filler port (F) on the hydraulic tank se-
curely.
11. Return plate (4) on oil filler port (F) of the hydraulic tank to
its original position, and fix it with bolt (3).
12. Close dirt cover (1).

CHECK HYDRAULIC FILTER

k Immediately after the engine is stopped, its parts and oil are still very hot, and may cause burn in-
jury. Accordingly, wait until all parts have cooled down before starting the work.
k When removing the oil filler cap, the oil may spout out. Turn it slowly to release the internal pres-
sure, then remove it.
1. Open dirt cover (1).
Open dirt cover (1) fully and it will be secured by cover
support lever (2).

2. Loosen bolt (3) of the hydraulic tank, move plate (4) on oil
filler port (F), turn the cap of oil filler port (F) slowly to re-
move it, and release the internal pressure.

PC45MR-5, PC55MR-5 40-43

TESTING IN ACCORDANCE WITH TESTING PROCEDURE 40 TROUBLESHOOTING

3. Remove cover mounting bolt (5), and remove cover (6).

The cover (6) may be jumped out by spring (7).
While pressing down cover (6), remove cover mounting
bolt (5).
4. After removing spring (7) and valve (8), take out element
(9).
5. Remove all dirt from the parts taken out, then wash it in
clean diesel fuel or flushing oil.
6. Install new element (9).
7. Check O-ring (10),and replace it with a new one if it is
damaged.
8. Place valve (8) and spring (7) on top of the element tem-
porarily.
9. While pressing cover (6) by hand, tighten cover mounting
bolt (5).
10. Start the engine.

11. Set the lock lever to FREE position (F).

12. Operate the work equipment control levers, and extend the
boom cylinder, bucket cylinder, and arm cylinder to their
stroke end.

13. Set the lock lever securely to LOCK position (L).

14. Stop the engine.
15. Tighten the cap of oil filler port on the hydraulic tank se-
curely.
By doing so, the hydraulic tank is pressurized.
NOTICE
If the hydraulic tank is not pressurized, air is sucked in
the pump and it affects the components badly.
16. Return plate (4) on oil filler port (F) of the hydraulic tank to
its original position, and fix it with bolt (3).
17. Close dirt cover (1).

40-44 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING TESTING IN ACCORDANCE WITH TESTING PROCEDURE

CHECK OIL LEVEL IN FINAL DRIVE CASE

k Since the oil may spurt out due to internal pressure, rotate the plug gradually to release the internal
pressure from its side, and then remove it carefully.
k Immediately after the engine is stopped, its parts and oil are still very hot, and may cause burn in-
jury. Accordingly, wait until all parts have cooled down before starting the work.
1. Be sure that plug (P) is at the right below.
2. Place a container under plug (G) to catch the drained oil.
3. Remove plug (G) with the hexagonal wrench.
4. Check the oil level.
The oil level should be near the lower edge of the hole of
plug (G).
5. If the oil level is low, remove plug (F) with the hexagonal
wrench and add oil.
Add oil until it overflows from the hole of plug (G).
6. After checking, tighten plugs (F) and (G).

BLEED AIR FROM FUEL SYSTEM

For the bleeding air from the fuel system, see “TESTING AND ADJUSTING”, “BLEED AIR FROM FUEL SYS-
TEM”.

BLEED AIR FROM HYDRAULIC SYSTEM

For bleeding air from the hydraulic system, see TESTING AND ADJUSTING, “BLEED AIR FROM HYDRAULIC
CIRCUIT”.

ELECTRICAL EQUIPMENT - CHECK METHOD

Check of battery terminal for looseness and corrosion
1. Open dirt cover (1).
Open dirt cover (1) fully and it will be secured by cover
support lever (2).
2. Remove the battery cover on the battery.
3. Check the battery cable terminals for looseness and corro-
sion.

PC45MR-5, PC55MR-5 40-45

TESTING IN ACCORDANCE WITH TESTING PROCEDURE 40 TROUBLESHOOTING

Check of battery disconnect switch position and check of battery ground for looseness and corrosion
(Optional mounting machine)
4. This is installed in the battery box inside the dirt cover.

5. Lift up rubber cover (2), and check that battery disconnect

switch (1) is ON position (marked with O).
REMARK
When shutting off the battery power supply before testing,
removal and installation, and etc., turn battery disconnect
switch (1) to OFF position (marked with I).

NOTICE
When turning battery disconnect switch (1) to OFF po-
sition (marked with I), check that the system operating
lamp is off.

6. Check the battery ground terminal at the back of battery disconnect switch (1) for looseness and corrosion.
Also, check the connected ground wiring terminal for
looseness and corrosion.

40-46 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING TESTING IN ACCORDANCE WITH TESTING PROCEDURE

Check of alternator terminal for looseness and corrosion

7. Pull engine rear cover (1) toward you to open it.
Open engine rear cover (1) fully and it is secured by rod
(2).
8. Open the floor.

9. Check alternator B terminal (3) for open circuit, looseness

and corrosion.

Check of starting motor terminal for looseness and corrosion

10. Check starting motor terminal B (1) and C terminal (2) for
open circuit, looseness and corrosion.

Check of battery voltage (with engine stopped)

11. Check the battery voltage by using the battery tester while the engine is stopped.
Check of battery electrolyte level
12. Check before operating the machine.
k Do not use the battery while its electrolyte level is below LOWER LEVEL. If it is used under that
condition, its inside becomes deteriorate, its service life is shortened, and it may lead to an ex-
plosion.
k Since the battery produces combustible gas that can explode, do not bring any open flame near
it.
k Battery electrolyte is dangerous. Take care that it does not come in contact with your eyes or
skin. If it does, wash it away with water and contact your doctor.
REMARK
• Do not add the electrolyte to the battery exceeding UPPER LEVEL line. If the electrolyte level is too
high, it may leak and cause damage to the paint surface or corrode other parts.
• When adding purified water in cold weather, add it before starting operations in the morning to prevent
the purified water from freezing.
• When checking the electrolyte level through the side face of the battery

PC45MR-5, PC55MR-5 40-47

TESTING IN ACCORDANCE WITH TESTING PROCEDURE 40 TROUBLESHOOTING

1) Open dirt cover (1).

Open dirt cover (1) fully and it will be secured by
cover support lever (2).

2) Wipe and clean the battery surface, especially

around the battery level lines with a wet cloth, and
check to see that the battery fluid is between the
UPPER LEVEL (U.L.) and LOWER LEVEL (L.L.)
lines.
NOTICE
Do not clean the battery with a dry cloth since
static electricity may cause an explosion.
3) If the electrolyte level is below the center between
the UPPER LEVEL (U.L.) and LOWER LEVEL
(L.L.) lines, remove cap (3) and add purified water
(example: commercially available battery fluid) to
the UPPER LEVEL (U.L.) line immediately.
4) After adding the purified water, tighten cap (3) se-
curely.
REMARK
If the purified water is added to above UPPER
LEVEL (U.L.) line, remove the fluid by using a sy-
ringe to lower the level to UPPER LEVEL (U.L.)
line. Neutralize the removed fluid with baking so-
da (sodium bicarbonate), then flush it away with a
large amount of water.
• When electrolyte level cannot be checked through the side face of the battery
1) Remove cap (3) on the top of battery. (described previously)
2) Look into filler port (5) and check the surface of
fluid. If the fluid level is below sleeve (6), always
add the purified water (such as a commercial bat-
tery fluid) until it reaches the bottom of sleeve (the
UPPER LEVEL).
• (A) Correct level: Since the electrolyte level
reaches to the sleeve bottom, the shape of
the electrode plates will appear distorted due
to the surface tension.
• (B) Low level: Electrolyte level does not
reach the bottom of sleeve, so pole plate ap-
pears straight and not to be warped.
3) After adding fluid, tighten cap (3).
REMARK
If the purified water is added to above UPPER LEVEL (U.L.) line, remove the fluid by using a sy-
ringe to lower the level to UPPER LEVEL (U.L.) line. Neutralize the removed fluid with baking soda
(sodium bicarbonate), then flush it away with a large amount of water.

40-48 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING TESTING IN ACCORDANCE WITH TESTING PROCEDURE

Check wiring harness for discoloration, burnt areas and cover peeling
13. Check the wiring harness and cables for discoloration and burn.
If discolored or burnt, the circuit may be shorted or grounded.
14. Check the wiring harnesses and cables for damage and peeling of the covers.
If any abnormality is found, repair or replace the wiring harness or cables.
Check for coming off of wiring harness clamp and sagging of wiring harness
15. Check wiring harness for sagging and looseness due to
coming off of harness clamp
NOTICE
In particular, carefully check the wiring harness
around the hot and movable parts.
16. If removed from the clamp, secure it with the clamp.

Check of grounding
NOTICE
Take special care of ground terminals for looseness and corrosion.
17. Open the front left cover at the lower part of the cab.
18. Check the connection of ground terminals (between cab
and revolving frame (1)) and (T01).
19. Open the floor. For details, see TESTING AND ADJUST-
ING, “METHOD FOR OPENING AND CLOSING FLOOR”.

20. Check the connection of ground terminal (2) of engine con-

troller.

PC45MR-5, PC55MR-5 40-49

TESTING IN ACCORDANCE WITH TESTING PROCEDURE 40 TROUBLESHOOTING

21. Check the connection of ground terminals (T02) and (T03).

Check for loose connector and damaged lock

22. Check the connectors for unlocking, and check the lock and connector housing for cracking.
23. Check lock of connectors (CE1) and (CE2) of engine con-
troller (1) for looseness.

Check of connector pin for corrosion, bends and deformation

24. Disconnect the connectors, and check their pins for corrosion, bending, sinking than other pins, and exten-
sion of female pins.
• If pins are defective, repair or replace them.
• If the pins are not shiny, apply contact restorer to them and connect and disconnect the connectors
several times to shine them. (If the pins do not become shiny, connect and disconnect the connectors
10 times)
Check of connector for entering of water and foreign material
25. Disconnect connectors, and check them for entering of wa-
ter or foreign material inside the connector.
NOTICE
If water or foreign material enters inside connector, the
seals may be defective. Check the seals for damage.

• If the seal is defective, repair or replace it.

40-50 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING TESTING IN ACCORDANCE WITH TESTING PROCEDURE

• Dry the inside of the connector with a dryer.

• Wipe and remove any foreign material inside connec-

tor with a cloth or others, and blow the air to clean the
connector.

Check of wiring harness for open or short circuit

26. Check the connection (crimped part) between connector
pins and wiring harness.
If it is open as shown as (A), repair or replace the wiring
harness or connector.
27. Visually check wiring harnesses for peeling of harness
covers and the pins for contact with adjacent pins due to
defective crimping.

Check fuse for blowing out and corrosion

28. When replacing a fuse, be sure to turn off the power (turn the starting switch to OFF position) and turn the
battery disconnect switch to OFF position.
• A fusible link is a large-capacity fuse.
• If a fuse is corroded and coated with white powder, or there is any play between the fuse and fuse
holder, replace the fuse.
• Replace each fuse with the one of the same capacity.

PC45MR-5, PC55MR-5 40-51

TESTING IN ACCORDANCE WITH TESTING PROCEDURE 40 TROUBLESHOOTING

29. The fuse holder is provided inside the cover under the op-
erator's seat.

30. Open the dirt cover and you will see fusible links of M09
(1), M05 (2), TM14 (3), and TM15 (4).

Check of alternator voltage (when engine speed is medium or higher)

31. Open the engine hood.
32. Connect the positive (+) lead of the multimeter to alternator (B) terminal and connect the negative (-) lead to
the chassis ground.
33. Start the engine and warm it up, and measure the voltage while running the engine at a medium or a higher
speed.
REMARK
If the voltage is abnormal, repair or replace the alternator.

40-52 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING ELECTRICAL SYSTEM TROUBLESHOOTING - PREPARATION

ELECTRICAL SYSTEM TROUBLESHOOTING - PREPARATION

• When performing troubleshooting of electric circuits of machine monitor, machine controller, engine control-
ler, and KOMTRAX terminal, expose the applicable connector part according to the following procedure.

Machine monitor
1. Remove floor mat (1).
2. Remove screws (2) (2 pieces), and remove cover (3).

3. Remove screws (4) (2 pieces), and remove cover (5).

4. Remove clamp (6), and disconnect connector F18 (7).

5. Remove mounting bolts (8) (4 pieces), and pull out ma-

chine monitor assembly (9) in the direction of the arrow.

PC45MR-5, PC55MR-5 40-53

ELECTRICAL SYSTEM TROUBLESHOOTING - PREPARATION 40 TROUBLESHOOTING

6. Remove screws (10) (8 pieces), and remove covers (11)

and (11a).

7. Connect or insert T-adapter for troubleshooting to connec-

tor (F15).

Machine controller
1. Remove KOMTRAX terminal.
2. Remove mounting bolts (1) (4 pieces), and remove cover
(2).

3. Connect the adapter for troubleshooting to connector

CP01 (3) and connector CP02 (4).
REMARK
Pull up lever (5) of connector CP01 (3) and connector
CP02 (4) in the direction of the arrow while pressing hook
(b).

40-54 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING ELECTRICAL SYSTEM TROUBLESHOOTING - PREPARATION

KOMTRAX terminal
1. Remove bolts (1), and remove cover (2).
(For the canopy spec)

(For the operator's cab spec)

2. Connect T-adapter for troubleshooting to connectors CK01

and CK02 of KOMTRAX terminal (3).

Engine controller
1. Open the floor. For details, see TESTING AND ADJUSTING, “METHOD FOR OPENING AND CLOSING
FLOOR”.
2. Connect or insert T-adapter for troubleshooting to connec-
tors (CE1) and (CE2) of engine controller (1).

PC45MR-5, PC55MR-5 40-55

PROCEDURE FOR TESTING AND TROUBLESHOOTING 40 TROUBLESHOOTING

PROCEDURE FOR TESTING AND TROUBLESHOOTING

Classification of troubleshooting
Mode Content
Display of code Troubleshooting by failure code
E mode Troubleshooting of electrical system
H mode Troubleshooting of hydraulic and mechanical systems
S mode Troubleshooting of engine

1. Check if action level and failure code are displayed on machine monitor:
REMARK
If multiple failure codes are displayed simultaneously, all codes are displayed repeatedly in order. Write
down those codes.
If action level and failure code are displayed on the standard screen of the machine monitor, perform the
troubleshooting for the “Display of code” corresponding to the displayed failure code.
2. Check a mechanical system failure code and an electrical system failure code with the abnormality record
function of the machine monitor.
1) Press F1, F2, and F3 in this order on the standard
screen while pressing F8 of the function switch.

2) On the service menu screen, press switch F1 twice on

the function switch, and select “03 Abnormality Re-
cord”.

3) Press switch F4 on the function switch to confirm, and

go to “Abnormality Record” screen.

40-56 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING PROCEDURE FOR TESTING AND TROUBLESHOOTING

4) Press switch F4 on the function switch to confirm it,

and go to “Mechanical Sys Abnormality Record”
screen.
5) Press switch F1 on the function switch to see if the
next failure code is displayed and write down all of the
failure codes.
REMARK
A failure code of the mechanical system cannot be de-
leted.
6) Press switch F3 on the function switch to return to
“Abnormality Record” screen.
7) On the service menu screen, press switch F1 twice on
the function switch, and select “03 Abnormality Re-
cord”.

8) Press switch F4 on the function switch to confirm, and

go to “Abnormality Record” screen.

9) Press switch F4 on the function switch to confirm it,

and go to “Electrical Sys Abnormality Record” screen.
10) Press switch F1 on the function switch to see if the
next failure code is displayed and write down all of the
failure codes.
REMARK
"E" on the left of a failure code indicates that the fail-
ure code is “active” (the failure remains or restoration
to normal has not been checked). A failure code hav-
ing no "E" on its left is a “non-active” one. Since it dis-
appears in clear mode, be sure to write it down.
• When a failure code is recorded:
Perform the troubleshooting for the “Display of code” corresponding to the displayed failure code.
REMARK
• If an electrical system failure code is recorded, clear all the codes once and reproduce them, and
then see if the failure is still detected.
• A failure code of the mechanical system cannot be deleted.
• When no failure code is recorded on abnormality record:

PC45MR-5, PC55MR-5 40-57

PROCEDURE FOR TESTING AND TROUBLESHOOTING 40 TROUBLESHOOTING

• A failure in electrical system that the machine cannot perform self-diagnosis or a failure in hydraul-
ic and mechanical system may have occurred, so check a phenomenon which seems to be a
failure again.
• Select the corresponding phenomenon from the table of “Symptom and troubleshooting numbers”,
and then perform troubleshooting corresponding to that phenomenon in “E mode”, “H mode”, and
“S mode”.
3. Clear all the failure codes in the electrical system abnormality record after the failure is repaired.
1) Press F1, F2, and F3 in this order while pressing F8 of the function switch to go to “clear mode”.
2) Press switch F8 on the function switch.
3) Press switch F4 on the function switch to clear all failure codes once
4) Press switch F3 on the function switch to return to
“Electrical Sys Abnormality Record” screen. See if any
failure code is still displayed and write down the dis-
played one.
5) Press switch F3 on the function switch to return to
“Abnormality Record” screen.
6) Write down the information of all the column.
REMARK
"E" on the left of a failure code as with "Electrical Sys
Abnormality Record" screen indicates that the failure
code is “active” (the failure remains or restoration to
normal has not been checked).
7) Press switch F8 on the function switch to clear all failure codes. Check if “Abnormality” is still displayed
or not, and write it down on a paper.
8) Press switch F3 on the function switch to return to “Abnormality Record” screen.

40-58 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS

SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS

Troubleshooting
No. Symptom of failure
Index
Action level and failure code
Action level is displayed on the machine monitor. Press function switch [F3] to
1
display "Current Abnormality"
Perform troubleshooting
2 Failure code is displayed on mechanical system abnormality record. for failure code
3 Failure code is displayed on Electrical Sys Abnormality Record.
Symptom related to engine
4 Engine startability is poor. S-4
5 Engine does not start. E-1, E-2, S-1
6 Engine does not crank when starting switch is turned to “START” position. S-1, E-1
7 Engine cranks but no exhaust smoke comes out. S-2
Fuel is being injected but engine does not start (misfiring: engine cranks but does
8 S-3
not start).
9 Engine does not pick up smoothly. S-5
10 Engine stops during operation. S-6, H-7
11 Engine runs rough or is unstable. S-7
12 Engine lacks power. S-8
13 KDPF gets clogged in a short time. S-9
14 Engine oil consumption is excessive. S-10
15 Engine oil becomes contaminated prematurely. S-11
16 Fuel consumption is excessive. S-12
17 Oil is in coolant (or coolant spurts back or coolant level goes down). S-13
18 Oil pressure drops. S-14
19 Fuel mixes into engine oil. S-15
20 Water mixes into engine oil (milky). S-16
21 Coolant temperature rises too high (overheating). S-17
22 Unusual noise is heard. S-18
23 Vibration is excessive. S-19
24 Air cannot be bled from fuel circuit. S-20
25 Automatic preheating system does not work. E-3
Auto-deceleration function does not operate or is not canceled while lever is oper-
26 E-16
ated.
Symptom related to work equipment, and swing and travel and blade system
27 All work equipment and travel speed or power is low. H-2
28 Swing and blade speed is low or power is low. H-3
29 Travel and blade speed or power is low. H-5
30 All work equipment, travel, swing and blade speed or power is low. H-6
31 Engine speed drops largely or engine stops. H-7

PC45MR-5, PC55MR-5 40-59

SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS 40 TROUBLESHOOTING

Troubleshooting
No. Symptom of failure
Index
32 All work equipments or travel does not operate. H-10
33 Swing or blade does not operate. H-11
34 Travel or blade does not operate. H-13
35 All work equipment, travel, swing or blade does not operate. H-14
36 Unusual noise is heard from around hydraulic pump. H-15
37 Fine control performance or response is poor. H-16
38 None of work equipment, swing or travel works. E-23
39 Any of work equipment, swing, and travel cannot be locked. E-24
Symptom related to work equipment
40 All work equipments speed or power is low. H-1
41 All work equipments and blade speed or power is low. H-4
42 All work equipments do not operate. H-9
43 All work equipments or blade does not operate. H-12
44 Boom speed or power is low. H-17
45 Arm speed or power is low. H-18
46 Bucket speed or power is low. H-19
47 Boom swing speed or power is low. H-21
48 Work equipment does not move in single operation. H-22
49 Hydraulic drift of boom is large. H-23
50 Hydraulic drift of arm is large. H-24
51 Hydraulic drift of bucket is large. H-25
In combined operation of work equipment, equipment having heavier load moves
52 H-27
slower.
53 Time lag of work equipment is large. H-28
Symptom related to blade
54 Blade does not operate. H-8
55 Blade speed is low or power is low. H-20
56 Hydraulic drift of blade is large (during blade RAISE or blade thrusting condition). H-26
Symptom related to travel
57 Machine does not travel straight. H-29
58 Machine deviates when moving off. H-30
59 Machine is not steered well or steering power is low. H-31
60 Travel speed is slow. H-32
61 Travel do not operate (both sides of tracks). H-33
62 One of tracks does not run. H-34
63 Travel speed does not change, or travel speed is too slow or fast. H-35
64 Travel speed does not change after the travel speed is changed. E-18
65 Alarm does not sound during travel. E-25

40-60 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS

Troubleshooting
No. Symptom of failure
Index
66 Alarm does not stop sounding while machine is stopped. E-26
Symptom related to swing
67 Upper structure does not swing both to the right and left. H-36
68 Upper structure swings only to the right or left. H-37
69 Swing acceleration or swing speed is low in both directions of right and left. H-38
Swing acceleration performance is poor or swing speed is slow in only one direc-
70 H-39
tion.
71 Upper structure overruns excessively when it stops swinging (both right and left). H-40
72 Upper structure overruns excessively when it stops swinging (either right or left). H-41
73 Shock is large when upper structure stops swinging. H-42
74 Large unusual noise is heard when upper structure stops swinging. H-43
75 Swing drift on a slope is large (while swing parking brake is applied). H-44
76 Swing drift on a slope is large (while swing parking brake is released). H-45
Symptom related to machine monitor
77 While preheating is working, preheating monitor does not light up. E-4
78 Coolant temperature monitor lights up in white while engine is running. E-5
79 Charge level monitor lights up in red while engine is running. E-6
80 Fuel level monitor lights up in red while engine is running. E-7
81 Engine coolant temperature monitor lights up in red while engine is running. E-8
82 Engine oil pressure monitor lights up in red while engine is running. E-9
83 Fuel gauge display does not move from minimum or maximum. E-10
84 Fuel gauge indicates incorrect amount (indicates neither full nor empty) E-11
Engine coolant temperature gauge display does not move from minimum or maxi-
85 E-12
mum.
Engine coolant temperature gauge indicates incorrect temperature (indicates nei-
86 E-13
ther full nor empty)
87 Some areas of machine monitor screen are not displayed. E-14
88 Function switch does not work. E-15
89 Alarm buzzer does not sound. E-19
90 Alarm buzzer does not stop sounding. E-20
91 Service meter is not displayed while starting switch is in OFF position. E-21
92 Service mode cannot be selected. E-22
93 Horn does not sound. E-27, E-28
94 Horn does not stop sounding. E-29, E-30
95 Lever operation signal is not displayed correctly with monitoring function. E-35 to E-37
Others
96 Working lamp or travel lamp does not light up (canopy spec). E-31
97 None of working lamp, travel lamp, or additional lamp lights up (cab spec). E-32
98 Windshield wiper does not operate while wiper switch is operated. E-33

PC45MR-5, PC55MR-5 40-61

SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS 40 TROUBLESHOOTING

Troubleshooting
No. Symptom of failure
Index
99 Window washer does not operate while window washer switch is operated. E-34
100 KOMTRAX system does not operate normally. E-38
“PROCEDURE FOR
TESTING AND TROU-
101 Air conditioner does not operate normally.
BLESHOOTING” in
Chapter 80

40-62 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE

INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE

The following types of information are described in the troubleshooting list and related circuit diagram. Fully un-
derstand the description and perform troubleshooting.
Action level Failure code
Display on Display on Failure name displayed on "Abnormality Record" screen of the machine
Failure
machine machine monitor
monitor monitor
Details of
Description of the failure detected by the machine monitor or controller
failure
Action of An action that is performed to protect the system and devices when a failure is detected by the ma-
controller chine monitor or controller
Problem on A problem that is displayed as a failure on the lift truck as a result of an action (shown above) that is
machine performed by the machine monitor or controller.
Related in-
Information related to the occurred failure and its troubleshooting
formation

No. Cause Procedure, measuring location, criteria, and remarks

1 Defective --- Contents of description
Open or short circuit • Procedure
2
in wiring harness • Measuring point
Open circuit in wiring "Between A and B" denotes measuring values such as voltage and resistance
harness between A and B.
3 "Between A and ground" means the measurement of voltage, resistance or
(wire breakage or de-
others between place A and the place which has a continuity with chassis
fective contact of con-
nector) frame such as unpainted hexagonal head bolt or bolt hole which has no rust,
etc.
Ground fault in wiring
• Criteria to judge probable causes (standard value), remarks
harness
4 How to use troubleshooting sheet
(contact with ground
circuit) • Perform troubleshooting procedures in following order.
5 Hot short circuit • If the check result does not meet the criteria, the probable cause described on
the left column is the actual cause of the failure.
• If the check result meet the criteria and there is no specific instruction, pro-
ceed to the next step (cause).
• If a defect is found and repaired, check that the defect has been corrected.
Failures in wiring harness
• Open circuit
When the wiring and the internal circuit of the connector are not connected
with each other, and there is no continuity
Short circuit in wiring
6 • Ground fault
harness
A wiring harness not to be connected to the GND (ground) circuit comes into
contact with the GND (ground) circuit or chassis accidentally.
• Hot short circuit
A wiring harness not to be connected to the power circuit comes into contact
with the power circuit accidentally.
• Short circuit
An independent wire in the harness abnormally comes into contact with one of
another wire. (Defective insulation in connector or others)

PC45MR-5, PC55MR-5 40-63

INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria, and remarks

Precautions for troubleshooting
(1) Connector number indication method and handling of T-adapter
For troubleshooting, insert or connect T-adapters as follows unless otherwise speci-
fied.
• When (male) or (female) is not indicated with a connector number, disconnect
the connector, and insert T-adapters to both sides of male and female.
• When (male) or (female) is indicated with a connector number, disconnect the
connector, and connect T-adapter to the indicated side of connector.
7 Defective controller • "Male and female" means male and female of connector pins, not connector
housings.
• Male and female of connector pins and housing in DT series, etc, are opposite
to those described in this manual. Take care.
(2) Pin number description sequence and tester lead handling
For troubleshooting, connect the positive (+) and negative (-) leads of a multimeter as
shown below unless otherwise specified.
• Connect the positive (+) lead to pin or wiring harness indicated first.
• Connect the negative (-) lead to a pin or wiring harness indicated second.

Related circuit diagram

This is the excerpted circuit diagram related to troubleshooting
• The circuit diagram contains the connector No., pin No., and connector color related to the failure.
• “/” is used in the connector No. in the following 2 cases.
• Abbreviation (3 letters in many cases)
Example) T/C: Abbreviation for Torque Converter
• Male side and female side have different connector Nos.
Example) BREAK OUT / E24
• The circuit diagram contains the destination or source of the branch line in a wiring harness.
• Arrow (↔): Approximate installation position on the machine
NO: Normally Open
NC: Normally Closed
• Signal names such as GND and 24 V are included in addition to connector numbers at junctions, etc. in
circuit diagrams.
• Except for GND and 24 V, a signal name indicated at a junction, etc. shows that the wire is connected to
another junction or controller at where the same signal name is indicated.

40-64 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING CONNECTORS LIST AND LAYOUT

CONNECTORS LIST AND LAYOUT

Three-dimen-
Number
Connector No. Connector type Location sional drawing
of pins
address
A01 SWP 12 Intermediate connector (if equipped) M-3, AQ-3
A02 DT 2 Intermediate connector (if equipped) L-4, AP-4
A03 DT 2 Bucket DUMP stop solenoid (if equipped) I-1, AM-1
CC01 070 14 ID key controller (if equipped) M-5, AQ-5
CE1 AMP 94 Engine controller H-1, AK-1
CE2 AMP 60 Engine controller H-1, AN-1
CK01 070 18 KOMTRAX terminal R-6, AV-8
CK02 070 12 KOMTRAX terminal R-6, AV-8
CP01 AMP 81 Machine controller R-5, AV-9
CP02 AMP 40 Machine controller R-5, AV-8
D01 SWP 8 Diode R-3, AV-3
E08 AMP 3 Boom bottom pressure sensor (if equipped) -
E09 DT 3 Boom angle sensor (if equipped) -
E10 DT 3 Arm angle sensor (if equipped) -
Boom swing NEUTRAL proximity switch (if
E14 SWP 3 -
equipped)
EGR VALVE - 4 EGR valve BN-2
F01 Y 2 Intermediate connector M-2, AQ-2
F02 Y 2 Intermediate connector M-2, AQ-2
F03 DT-C 12 Intermediate connector O-1, AS-1
F04 DT-B 12 Intermediate connector O-1, AS-1
F05 DT-D 12 Intermediate connector N-1, AR-1
F06 DT-A 12 Intermediate connector O-1, AS-1
F07 DTM 2 Seat belt switch N-9, AR-9
F08 DT 4 Optional power supply (cab) AV-6
F09 DT 3 PPC oil pressure lock switch R-5, AV-5
F10 SWP 6 Engine shutdown secondary switch R-3, AV-3
F11 DT 3 Intermediate connector (cab) M-3, AQ-3
F12 DT 2 External power supply socket M-4, AQ-4
F13 DTM 2 Horn switch M-6, AQ-6
F14 DT 2, 4 Optional power supply (canopy) S-4, AW-4
F15 070 12 PM200 monitor M-5, AQ-5
F16 DTM 6 Engine diagnosis device (SA-D) connector R-4, AV-4
F17 DT 3 Fuel control dial M-7, AQ-7
F18 DT-A 12 Intermediate connector M-3, AQ-3
F19 SUMITOMO 3 Room lamp (cab) P-9, AT-9

PC45MR-5, PC55MR-5 40-65

CONNECTORS LIST AND LAYOUT 40 TROUBLESHOOTING

Three-dimen-
Number
Connector No. Connector type Location sional drawing
of pins
address
F21 M 2 Cab revolving lamp (cab) (if equipped) Q-9, AU-9
F22 M 2 Intermediate connector (cab) P-9, AS-9
F22A DT 2 Cab travel lamp (cab) AD-6, BH-6
Additional working lamp/Cab additional lamp
F22B DT 2 Z-8, BD-8
(cab) (if equipped)
F23 M 3 Intermediate connector (cab) O-9, AT-9
F24 M 3 Intermediate connector (cab) Q-9, AU-9
F25 DT-A 8 Intermediate connector N-1, AR-1
F26 DT-A 12 ATT switch lever (if equipped) M-6, AQ-6
F27 DT 4 Wiper motor and switch (cab) Z-1, BD-1
F28 YAZAKI 2 Buzzer M-6, AQ-6
F29 DT-T 12 Attachment switch lever AV-5
F31 - 2 Speaker (left) (cab) AD-4, BH-4
F32 - 2 Speaker (right) (cab) AD-3, BH-3
F37 DT 12 Service connector Q-1, AU-1
F38 DT 2 Travel speed increase switch M-5, AQ-5
F50 YAZAKI 2 Buzzer AV-5
F51 DT 2 Quick coupler valve AR-1
F52 DT 2 Revolving lamp AU-9
F53 YAZAKI 2 Optional power supply AR-9
FB1 Terminal 15 Fuse box Q-1, AU-1
HI PRESS PUMP - 2 SUPPLY PUMP BK-2
INJECTOR#1 - 2 Injector #1 BK-8
INJECTOR #2 - 2 Injector #2 BL-8
INJECTOR #3 - 2 Injector #3 BM-8
INJECTOR #4 - 2 Injector #4 BN-7
INTAKE THROT- Intake throttle BI-3
- 6
TLE
J01 J 20 Junction connector R-2, AV-2
J02 J 20 Junction connector R-2, AV-2
J03 J 20 Junction connector R-2, AV-2
M01 Y 090 2 2 Horn I-1, AL-1
M01 YAZAKI PA 9 Radio (if equipped) AC-2, AL-1
M01A - 3 Radio (if equipped) AB-1, BF-1
M01B M 3 AUX jack (if equipped) AD-5, AD-5
M02 KES 2 Window washer motor (cab) D-7, AH-7
M05 L 2 Fusible link F-9, AJ-9
M06 SDD 3 Fuel level sensor G-9, AK-9

40-66 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING CONNECTORS LIST AND LAYOUT

Three-dimen-
Number
Connector No. Connector type Location sional drawing
of pins
address
M07 DT 2 TVC resistor C-7, AG-7
M08 DT 2 Travel alarm C-7, AG-7
M09 M 2 Fusible link E-8, AI-8
M10 - 3 Alternator J-9, AN-9
M11 DT 2 PC-EPC valve (TVC solenoid) L-4, AP-4
M12 SWP 1 Intermediate connector (cab) (if equipped) L-5, AP-5
M13 YAZAKI 1 Air conditioner compressor solenoid clutch K-9, AK-1
M13 - 4 Glow plug relay G-1, AK-1
M14 X 2 Feed pump L-5, AP-5
M15 SUMITOMO 6 EGR valve relay G-1, AK-1
M16 - 4 Starting motor relay L-2, AP-2
M17 DT 2 Travel speed increase solenoid J-1, AM-1
M18 DT 2 PPC lock solenoid K-1, AL-1
M22 DT 2 System operating lamp (if equipped) F-9, AJ-9
M23 SUMITOMO 1 Glow plug L-6, AP-6
M24 SUMITOMO 2 Oil pressure switch L-5, AP-5
M25 AMP 6 KDPF differential pressure sensor L-8, AP-8
M26 FCI 2 KDPF inlet temperature sensor L-7, AP-7
M27 FCI 2 KDPF intermediate temperature sensor L-7, AP-7
M31 AMPSEAL 8 Intermediate connector L-5, AP-5
M32 AMPSEAL 12 Intermediate connector L-8, AP-8
M33 AMPSEAL 12 Intermediate connector L-5, AP-5
M34 AMPSEAL 12 Intermediate connector L-6, AP-6
P01 X 2 Work equipment PPC pressure switch K-1, AO-1
P02 AMP 3 Travel PPC pressure sensor L-2, AP-2
Swing parking brake cancel PPC pressure sen- K-1, AO-1
P03 AMP 3
sor
P04 DT 4 Connector for service L-3, AP-4
R01 MICRO ISO 5 Starting motor cut-off relay (PPC lock) M-2, AQ-2
R02 MICRO ISO 5 PPC lock solenoid relay R-4, AV-4
R03 MICRO ISO 5 Horn relay M-2, AQ-2
R04 MICRO ISO 5 Working lamp relay R-4, AV-4
R05 MICRO ISO 5 Additional lamp relay N-1, AR-1
R06 MICRO ISO 5 Starting motor cut-off relay (personal code) R-4, AV-4
R07 MICRO ISO 5 C circuit dummy relay N-1, AR-1
R08 MICRO ISO 5 Revolving lamp relay P-1, AV-3
S02 SWP 6 Working lamp switch M-8, AQ-8
S05_1 Terminal 1 Quick coupler switch AV-7

PC45MR-5, PC55MR-5 40-67

CONNECTORS LIST AND LAYOUT 40 TROUBLESHOOTING

Three-dimen-
Number
Connector No. Connector type Location sional drawing
of pins
address
S05_2 Terminal 1 Quick coupler switch AV-7
S05_3 Terminal 1 Quick coupler switch AV-7
S05_4 Terminal 1 Quick coupler switch AV-7
S21 Terminal 6 Pump secondary drive switch P-1
S23 Terminal 3 Lock lever automatic lock cancel switch Q-1
S25 SWP 8 Pump secondary drive switch P-1
S30 M 3 Model selection connector R-7
SENSOR, CAM Cam acceleration sensor AJ-4
- 3
SPEED
SENSOR, COOL- Coolant temperature sensor AJ-5
- 2
ANT TEMP
SENSOR, CRANK Crankshaft speed sensor AE-5
- 2
SPEED
SENSOR, EGR EGR gas temperature sensor AE-7
- 2
GAS TEMP
SENSOR, EGR EGR pressure sensor AJ-6
- 6
PRESS
SENSOR, EX- Exhaust gas temperature sensor AE-6
- 2
HAUST TEMP
SENSOR, FRESH
- 2 Fresh air temperature sensor AF-2
INTAKE TEMP
SENSOR, FUEL Fuel temperature sensor AH-2
- 2
TEMP
SENSOR, IN- Intake air temperature sensor AJ-7
- 2
TAKE TEMP
SENSOR, RAIL Rail pressure sensor AI-2
- 3
PRESS
T01 Terminal 1 Ground (controller) O-1, AS-1
T02 Terminal 1 Ground L-2, AP-2
T03 Terminal 1 Ground (engine) L-3, AP-3
TF1 Terminal 1 Starting switch N-8, AR-8
TF3 Terminal 1 Starting switch N-8, AR-8
TF4 Terminal 1 Starting switch N-8, AR-8
TM1 Terminal 1 Battery B-6, AF-6
TM2 Terminal 1 Alternator I-9, AM-9
TM6 Terminal 1 Starting motor K-9, AO-9
TM13 Terminal 1 Fuse box A-5, AE-5
TM14 Terminal 1 Fuse box E-8, AI-8
TM15 Terminal 1 Fuse box F-1, AJ-1
TM16 Terminal 1 Starting motor L-4, AP-4
V01 DT 2 EPC (1ST ATT A port) (if equipped) -

40-68 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING CONNECTORS LIST AND LAYOUT

Three-dimen-
Number
Connector No. Connector type Location sional drawing
of pins
address
V02 DT 2 EPC (1ST ATT B port) (if equipped) -
W01 DT 2 Intermediate connector E-1, AI-1
W02 DT 3 Working lamp B-2, AF-2
W03 DT 2 Travel lamp (canopy) L-1, AW-2

PC45MR-5, PC55MR-5 40-69

CONNECTORS LIST AND LAYOUT 40 TROUBLESHOOTING

1/11

40-70 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING CONNECTORS LIST AND LAYOUT

2/11

PC45MR-5, PC55MR-5 40-71

CONNECTORS LIST AND LAYOUT 40 TROUBLESHOOTING

3/11

40-72 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING CONNECTORS LIST AND LAYOUT

4/11 (canopy specifications)

PC45MR-5, PC55MR-5 40-73

CONNECTORS LIST AND LAYOUT 40 TROUBLESHOOTING

5/11 (cab specifications)

40-74 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING CONNECTORS LIST AND LAYOUT

6/11 (quick coupler specifications)

PC45MR-5, PC55MR-5 40-75

CONNECTORS LIST AND LAYOUT 40 TROUBLESHOOTING

7/11 (quick coupler specifications)

40-76 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING CONNECTORS LIST AND LAYOUT

8/11 (quick coupler specifications)

PC45MR-5, PC55MR-5 40-77

CONNECTORS LIST AND LAYOUT 40 TROUBLESHOOTING

9/11 (canopy specifications, quick coupler specifications)

40-78 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING CONNECTORS LIST AND LAYOUT

10/11 (cab specifications, quick coupler specifications)

PC45MR-5, PC55MR-5 40-79

CONNECTORS LIST AND LAYOUT 40 TROUBLESHOOTING

11/11

40-80 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING CONNECTOR CONTACT IDENTIFICATION (FOR 4D88E-7 ENGINE)

CONNECTOR CONTACT IDENTIFICATION (FOR 4D88E-7 ENGINE)

No. Equipment Equipment
of (Sec. 90 Electric dia- (Engine shop man- Connecter maker Detail of interface and pin No.
pins gram) ual)

1 GLOW PLUG Glow plug YAZAKI

SENSOR,EXHAUST Exhaust manifold

2 FCI
TEMP temperature sensor

SENSOR,EGR GAS EGR gas temperature

TEMP sensor
2 DELPHI
SENSOR,INTAKE Intake manifold tem-
TEMP perature sensor

SENSOR,FRESH New air temperature

2 Tyco
INTAKE TEMP sensor

OIL PRESS
2 Oil pressure switch SUMITOMO
SWITCH

SENSOR, DPF IN- KDPF inlet tempera-

LET TEMP ture sensor
2 FCI
SENSOR, DPF IN- KDPF intermediate
SIDE TEMP temperature sensor

PC45MR-5, PC55MR-5 40-81

CONNECTOR CONTACT IDENTIFICATION (FOR 4D88E-7 ENGINE) 40 TROUBLESHOOTING

No. Equipment Equipment

of (Sec. 90 Electric dia- (Engine shop man- Connecter maker Detail of interface and pin No.
pins gram) ual)

SENSOR, COOL- Cooling water tem-

2 Tyco
ANT TEMP perature sensor

2 INJECTOR Injector BOSCH

HI PRESS PUMP High-pressure pump

2 SENSOR, FUEL Fuel temperature BOSCH
TEMP sensor

SENSOR, CRANK
2 Crank speed sensor BOSCH
SPEED

SENSOR, RAIL
3 Rail pressure sensor BOSCH
PRESS

SENSOR, CAM
3 Cam speed sensor BOSCH
SPEED

40-82 PC45MR-5, PC55MR-5

CONNECTOR CONTACT IDENTIFICATION (FOR 4D88E-7 ENGINE) 40 TROUBLESHOOTING

No. Equipment Equipment

of (Sec. 90 Electric dia- (Engine shop man- Connecter maker Detail of interface and pin No.
pins gram) ual)

8 HARNESS, ENG Junction coupler Tyco

12 HARNESS, ENG Junction coupler Tyco

40-84 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING T-BRANCH BOX AND T-BRANCH ADAPTER TABLE

T-BRANCH BOX AND T-BRANCH ADAPTER TABLE

(Rev.2014.11)

PC45MR-5, PC55MR-5 40-89

T-BRANCH BOX AND T-BRANCH ADAPTER TABLE 40 TROUBLESHOOTING

T-adapter kit

Number of pins

Non-kit part
799-A65-4600

799-902-9300
Part No. Part name ID marking

799-601-4620 Adapter for controller (ENG-T4) 4 799-601-4620 ●

799-601-4630 Adapter for controller (ENG-T4) 2 799-601-4630 ●
799-601-4640 Adapter for controller (ENG-T4) 2 799-601-4640 ●
799-601-4651 Adapter for controller (ENG-T4) 24 799-601-4651 ●
799-601-4660 Adapter for controller (ENG-T4) 3 799-601-4660 ●
799-902-9310 Adapter for control box 19 799-902-9310 ●
799-902-9320 Adapter for IMU 10 799-902-9320 ●
799-902-9330 Adapter for MS cylinder 6 799-902-9330 ●
KDPF differential pressure sensor
799T-601-4611 4 799T-601-4611 ●
short socket adapter
KDPF outlet pressure sensor short
799T-601-4670 4 799T-601-4670 ●
socket adapter
799T-601-4680 KDPF dummy temperature sensor 4 799T-601-4680 ●

40-90 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING FUSE LOCATION TABLE

FUSE LOCATION TABLE

• This connection table shows the devices which receive supply from each power source of the fuse box. (A
switched power supply is the power which is supplied while the starting switch is in ON position and a con-
tinuous power supply is the power which is supplied even while the starting switch is in ON and OFF posi-
tions.)
• When performing troubleshooting related to the electrical system, it is desirable to check the fuses and fusi-
ble links whether the power supply is normally supplied at first.
Connection table of fuse box
Canopy specifications
Type of pow- Power supply Fuse Fuse ca-
Destination of power
er supply to fuse No. pacity
Working lamp relay, additional working lamp relay, and pump
1 5 A
secondary drive switch
2 10 A Solenoid valve
3 5 A PPC hydraulic lock solenoid
4 10 A Spare
Fusible link
Switched M05 (65 A) 5 10 A Travel alarm, fuel pump, and horn
power supply 6 10 A Spare
7 10 A Spare
8 10 A Heater
9 10 A External power supply
Starting switch
10 5 A ACC signal
ACC
11 10 A Working lamp and travel lamp
12 5 A System operating lamp (if equipped)
Continuous Fusible link
13 10 A Machine monitor and controller
power supply M09 (45 A)
14 20 A Engine controller
15 20 A EGR valve

PC45MR-5, PC55MR-5 40-91

FUSE LOCATION TABLE 40 TROUBLESHOOTING

Canopy specifications (quick coupler specifications)

Type of pow- Power supply Fuse Fuse ca-
Destination of power
er supply to fuse No. pacity
Working lamp relay, additional working lamp relay, and pump
1 5 A
secondary drive switch
2 10 A Solenoid valve
3 5 A PPC hydraulic lock solenoid
4 10 A Spare
Fusible link
Switched M05 (65 A) 5 10 A Travel alarm, fuel pump, and horn
power supply 6 10 A Spare
7 10 A Spare
8 10 A Quick coupler
9 10 A External power supply
Starting switch
10 5 A ACC signal and fuel pump
ACC
11 10 A Working lamp and travel lamp
12 5 A System operating lamp (if equipped)
Continuous Fusible link
13 10 A Machine monitor and controller
power supply M09 (45 A)
14 20 A Engine controller
15 20 A EGR valve

Cab specifications
Type of pow- Power supply Fuse Fuse ca-
Destination of power
er supply to fuse No. pacity
Working lamp relay, additional working lamp relay, and pump
1 5 A
secondary drive switch
2 10 A Solenoid valve
3 5 A PPC hydraulic lock solenoid
4 10 A Room lamp, radio, and windshield wiper
Fusible link
Switched M05 (65 A) 5 10 A Travel alarm, fuel pump, and horn
power supply 6 10 A Spare
7 10 A Spare
8 20 A Air conditioner and heater
9 10 A External power supply
Starting switch
10 5 A ACC signal
ACC
11 30 A Working lamp, travel lamp, and additional working lamp
12 10 A System operating lamp (if equipped), radio
Continuous Fusible link
13 10 A Machine monitor and controller
power supply M09 (45 A)
14 20 A Engine controller
15 20 A EGR valve

40-92 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING FUSE LOCATION TABLE

Cab specifications (quick coupler specifications)

Type of pow- Power supply Fuse Fuse ca-
Destination of power
er supply to fuse No. pacity
Working lamp relay, additional working lamp relay, and pump
1 5 A
secondary drive switch
2 10 A Solenoid valve
3 5 A PPC hydraulic lock solenoid
4 10 A Room lamp, radio, and windshield wiper
Fusible link
Switched M05 (65 A) 5 10 A Travel alarm, fuel pump, and horn
power supply 6 10 A Revolving lamp
7 10 A Quick coupler
8 20 A Air conditioner and heater
9 10 A External power supply
Starting switch
10 5 A ACC signal
ACC
11 30 A Working lamp, travel lamp, and additional working lamp
12 10 A Radio and system operating lamp
Continuous Fusible link
13 10 A Machine monitor and controller
power supply M09 (45 A)
14 20 A Engine controller
15 20 A EGR valve

Locations of fusible links

* : Open the dirt cover, and you will see the fusible links M09
(1), M05 (2), TM14 (3), and TM15 (4).

PC45MR-5, PC55MR-5 40-93

FUSE LOCATION TABLE 40 TROUBLESHOOTING

Locations of fuse boxes and fuse No.

* : The fuse holder is provided inside the cover under the oper-
ator's seat.

40-94 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING FAILURE CODES TABLE

FAILURE CODES TABLE

Failure Applicable Action History cate-
Failure (Displayed on screen) Remarks
code component level gory
Electrical
989L00 Engine Controller Lock Caution 1 MON -
system
Electrical
989M00 Engine Controller Lock Caution 2 MON -
system
Electrical
989N00 Engine Controller Lock Caution 3 MON -
system
Electrical
AQ20R1 KCSF Manual Stationary Regeneration Request MACHINE L01
system
Mechanical
B@BCNS Eng Water Overheat MACHINE L02
system
Electrical
D19JKZ Personal Code Relay Open Circuit or Short Circuit MON L03
system
Electrical
D811MC KOMTRAX Malfunction KOMTRAX -
system
Electrical
D862KA GPS Antenna Open Circuit KOMTRAX -
system
Electrical
D8ALKA System Operating Lamp Open Circuit (KOMTRAX) KOMTRAX -
system
Electrical
D8ALKB System Operating Lamp Short Circuit (KOMTRAX) KOMTRAX -
system
Electrical
D8AQKR CAN 2 Defective Communication (KOMTRAX) MON ―
system
Electrical
DAF0KT EEPROM Error (Monitor) MON L03
system
Electrical
DAF0MB Monitor ROM Abnormality MON -
system
Electrical
DAF0MC Monitor Malfunction MON -
system
Electrical
DAF3KK Main Power Voltage Low Error (Monitor) MON -
system
Electrical
DAF9KQ Model Selection Signal Mismatch (Monitor) MON L03
system
Electrical
DAFGMC GPS Module Malfunction KOMTRAX -
system
Electrical
DAFLKA System Operating Lamp Open Circuit (Monitor) MON -
system
Electrical
DAFLKB System Operating Lamp Short Circuit (Monitor) MON -
system
Electrical
DAFQKR CAN 2 Defective Communication (Monitor) KOMTRAX -
system
CAN 2 Defective Communication (Engine Control- Electrical
DB2QKR MON L03
ler) system
Mechanical
DBH0MC Machine Controller Malfunction MACHINE -
system

PC45MR-5, PC55MR-5 40-95

FAILURE CODES TABLE 40 TROUBLESHOOTING

Failure Applicable Action History cate-

Failure (Displayed on screen) Remarks
code component level gory
Mechanical
DBH2KK Mcn Solenoid Power Low Error MACHINE L03
system
Mechanical
DBH5KP 5V Sensor 1 Power Voltage Low Error MACHINE -
system
5V Sensor 1 Power Voltage Low Error (FOR PRO- Mechanical
DBH5KP MACHINE -
PORTIONAL LEVER SPEC) system
Electrical
DBH9KQ Model Selection Signal Mismatch (MCN Controller) MACHINE L01
system
Mechanical
DBHLKA Operating Lamp Open Circuit(Mcn Con) MACHINE -
system
Mechanical
DBHLKB Operating Lamp Short Circuit(Mcn Con) MACHINE -
system
Controller Area NW 2 Defect Communicat (Machn Electrical
DBHQKR MON L03
Con) system
Electrical
DDNRKA W/E Lever Lock SW Open Circuit MACHINE L03
system
Electrical
DDNRKY W/E Lever Lock SW Short Circuit MACHINE L03
system
Electrical
DDNS00 Lock Lever Auto Lock Release SW On MACHINE -
system
Electrical
DDWLKA Breaker Switch Open Circuit or Ground Fault MACHINE -
system
Electrical
DDWLKB Breaker Switch Hot Short Circuit MACHINE -
system
Electrical
DFB1KZ Service Lever Potentio 1 Open or Short Circuit MACHINE L01
system
Electrical
DFB3L8 Service Lever 1 Potentio Signal Incompatibility MACHINE -
system
Electrical
DFB5KZ Service Lever sub-Potentio 1 Open or Short Circuit MACHINE -
system
Electrical
DHS1MA Swing PPC Pressure Sensor System Abnormality MACHINE L01
system
Electrical
DHS5MA Travel PPC Pressure Sensor Error MACHINE L01
system
Electrical
DKULKA PPC Lock Relay Open Circuit MACHINE L03
system
Electrical
DKULKB PPC Lock Relay Short Circuit MACHINE L03
system
Electrical
DKULKY PPC Lock Relay Hot Short Circuit MACHINE L03
system
Electrical
DV00KB Buzzer Output Short Circuit MON L01
system
Electrical
DV20KB Travel Alarm Short Circuit MACHINE L01
system
Electrical
DW43KA Travel Speed Solenoid Open Circuit MACHINE L01
system

40-96 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING FAILURE CODES TABLE

Failure Applicable Action History cate-

Failure (Displayed on screen) Remarks
code component level gory
Electrical
DW43KB Travel Speed Solenoid Short Circuit MACHINE L01
system
Electrical
DW43KY Travel Speed Solenoid Hot Short Circuit MACHINE L01
system
Electrical
DW4CKY PPC Lock Solenoid Hot Short Circuit MACHINE L03
system
Electrical
DXA8KA Pump PC-EPC Solenoid Open Circuit MACHINE L03
system
Electrical
DXA8KB Pump PC-EPC Solenoid Short Circuit MACHINE L03
system
Attachment Flow Regulating EPC 2 Solenoid Open Electrical
DXE7KA MACHINE -
Circuit system
Attachment Flow Regulating EPC 2 Solenoid Short Electrical
DXE7KB MACHINE -
Circuit system
Attachment Flow Regulating EPC 2 Hot Short Cir- Electrical
DXE7KY MACHINE -
cuit system
Attachment Flow Regulating EPC 5 Solenoid Open Electrical
DXEAKA MACHINE -
Circuit system
Attachment Flow Regulating EPC 5 Solenoid Short Electrical
DXEAKB MACHINE -
Circuit system
Attachment Flow Regulating EPC 5 Hot Short Cir- Electrical
DXEAKY MACHINE -
cuit system
#B0008 FAILURE CODE [#B0008] No Signal on Both Crank ENG L04 Electrical *1
and Cam Speed Sensor system
#B000F FAILURE CODE [#B000F] PLV Open Valve ENG L03 Electrical *1
system
#B0088 FAILURE CODE [#B0088] Actual Rail Pressure ENG L03 Electrical *1
Rise Error system
#B0093 FAILURE CODE [#B0093] Rail Press Deviation Er- ENG L03 Electrical *1
ror in Act Rail Press Rise system
#B0094 FAILURE CODE [#B0094] Rail Press Deviation Er- ENG L03 Electrical *1
ror in Act Rail Press Drop system
#B0112 FAILURE CODE [#B0112] New Air Temperature ENG L01 Electrical *1
Sensor Error (Low Voltage) system
#B0113 FAILURE CODE [#B0113] New Air Temperature ENG L01 Electrical *1
Sensor Error (High Voltage) system
#B0117 FAILURE CODE [#B0117] Cooling Water Tempera- ENG L03 Electrical *1
ture Sensor Error (Low Volt) system
#B0118 FAILURE CODE [#B0118] Cooling Water Tempera- ENG L03 Electrical *1
ture Sens Error (High Volt) system
#B0122 FAILURE CODE [#B0122] Accelerator Sensor 1 ENG L03 Electrical *1
(Low voltage) system
#B0123 FAILURE CODE [#B0123] Accelerator Sensor 1 ENG L03 Electrical *1
(High voltage) system
#B0168 FAILURE CODE [#B0168] Fuel Temperature Sen- ENG L03 Mechanical *1
sor Temperature Abnormal High system

PC45MR-5, PC55MR-5 40-97

FAILURE CODES TABLE 40 TROUBLESHOOTING

Failure Applicable Action History cate-

Failure (Displayed on screen) Remarks
code component level gory
#B0182 FAILURE CODE [#B0182] Fuel Temperature Sen- ENG L03 Electrical *1
sor Error (Low Voltage) system
#B0183 FAILURE CODE [#B0183] Fuel Temperature Sen- ENG L03 Electrical *1
sor Error (High Voltage) system
#B0192 FAILURE CODE [#B0192] Rail Pressure Sensor Er- ENG L03 Electrical *1
ror (Low Voltage) system
#B0193 FAILURE CODE [#B0193] Rail Pressure Sensor Er- ENG L03 Electrical *1
ror (High Voltage) system
#B0201 FAILURE CODE [#B0201] Injector of 1st Cylinder ENG L03 Electrical *1
OpenC (Inherent Location) system
#B0202 FAILURE CODE [#B0202] Injector of 2nd Cylinder ENG L03 Electrical *1
OpenC (Inherent Location) system
#B0203 FAILURE CODE [#B0203] Injector of 3rd Cylinder ENG L03 Electrical *1
OpenC (Inherent Location) system
#B0204 FAILURE CODE [#B0204] Injector of 4th Cylinder ENG L03 Electrical *1
OpenC (Inherent Location) system
#B0219 FAILURE CODE [#B0219] Overspeed ENG L04 Mechanical *1
system
#B0236 FAILURE CODE [#B0236] EGR Low Pres Side ENG L03 Electrical *1
Sens Error (Abnorma Learn Value) system
#B0237 FAILURE CODE [#B0237] EGR Low Pressure Side ENG L03 Electrical *1
Sensor Error (Low Voltage) system
#B0238 FAILURE CODE [#B0238] EGR Low Pressure Side ENG L03 Electrical *1
Sensor Error (High Voltage) system
#B0262 FAILURE CODE [#B0262] Injector of 1st Cylinder ENG L03 Electrical *1
Coil Short Circuit system
#B0265 FAILURE CODE [#B0265] Injector of 2nd Cylinder ENG L03 Electrical *1
Coil Short Circuit system
#B0268 FAILURE CODE [#B0268] Injector of 3rd Cylinder ENG L03 Electrical *1
Coil Short Circuit system
#B0271 FAILURE CODE [#B0271] Injector of 4th Cylinder ENG L03 Electrical *1
Coil Short Circuit system
#B02E8 FAILURE CODE [#B02E8] Intake Throttle Open Po- ENG L03 Electrical *1
sition Sens Error (Low V) system
#B02E9 FAILURE CODE [#B02E9] Intake Throttle Open Po- ENG L03 Electrical *1
sition Sens Error (High V) system
#B0336 FAILURE CODE [#B0336] Crank Signal Error ENG L03 Electrical *1
system
#B0337 FAILURE CODE [#B0337] No Crank Signal ENG L03 Electrical *1
system
#B0341 FAILURE CODE [#B0341] Cam Signal Error ENG L01 Electrical *1
system
#B0342 FAILURE CODE [#B0342] No Cam Signal ENG L01 Electrical *1
system
#B0403 FAILURE CODE [#B0403] Open Circuit Between ENG L03 Electrical *1
the EGR Motor Coils system

40-98 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING FAILURE CODES TABLE

Failure Applicable Action History cate-

Failure (Displayed on screen) Remarks
code component level gory
#B0404 FAILURE CODE [#B0404] EGR Voltage High Error ENG L03 Electrical *1
system
#B040C FAILURE CODE [#B040C] Intake Manifold Temper- ENG L03 Electrical *1
ature Sens Error (Low Volt) system
#B040D FAILURE CODE [#B040D] Intake Manifold Temper- ENG L03 Electrical *1
ature Sens Error (High Volt) system
#B041C FAILURE CODE [#B041C] EGR Gas Temperature ENG L03 Electrical *1
Sensor Error (Low Voltage) system
#B041D FAILURE CODE [#B041D] EGR Gas Temperature ENG L03 Electrical *1
Sensor Error (High Voltage) system
#B0420 FAILURE CODE [#B0420] KDPF Inter Temperature ENG L03 Electrical *1
Low Error system
#B0471 FAILURE CODE [#B0471] EGR High Pres Side ENG L03 Electrical *1
Sens Error (Abnorm Learn Value) system
#B0472 FAILURE CODE [#B0472] EGR High Pressure Side ENG L03 Electrical *1
Sensor Error (Low Voltage) system
#B0473 FAILURE CODE [#B0473] EGR High Pressure Side ENG L03 Electrical *1
Sensor Error (High Voltage) system
#B0488 FAILURE CODE [#B0488] EGR Position Sensor Er- ENG L03 Electrical *1
ror system
#B049D FAILURE CODE [#B049D] EGR Initialization Error ENG L03 Electrical *1
system
#B0541 FAILURE CODE [#B0541] Startup Assist Relay ENG L01 Electrical *1
GND Short Circuit system
#B0543 FAILURE CODE [#B0543] Startup Assist Relay ENG L01 Electrical *1
Open Circuit system
#B0545 FAILURE CODE [#B0545] Exhaust Manifold Tem- ENG L03 Electrical *1
perature Sens Error (Low Volt) system
#B0546 FAILURE CODE [#B0546] Exhaust Manifold Tem- ENG L03 Electrical *1
perature Sens Error (HighVolt) system
#B0601 FAILURE CODE [#B0601] EEPROM Memory Dele- ENG L03 Electrical *1
tion Error system
#B0611 FAILURE CODE [#B0611] Injector Drive IC Error ENG L04 Electrical *1
system
#B0627 FAILURE CODE [#B0627] SCV(MPROP) (Open ENG L03 Electrical *1
Circuit) system
#B0629 FAILURE CODE [#B0629] SCV(MPROP) (High ENG L03 Electrical *1
Side VB Short) system
#B062A FAILURE CODE [#B062A] SCV(MPROP) (Drive ENG L03 Electrical *1
Current High Error) system
#B0660 FAILURE CODE [#B0660] No-load of Throttle Valve ENG L03 Electrical *1
Drive H Bridge Circuit system
#B068A FAILURE CODE [#B068A] Main Relay Early Open- ENG L01 Electrical *1
ing system
#B068B FAILURE CODE [#B068B] Main Relay Contact ENG L01 Electrical *1
Stuck system

PC45MR-5, PC55MR-5 40-99

FAILURE CODES TABLE 40 TROUBLESHOOTING

Failure Applicable Action History cate-

Failure (Displayed on screen) Remarks
code component level gory
#B1146 FAILURE CODE [#B1146] Injector Drive Circuit ENG L03 Electrical *1
(Bank1) Short Circuit system
#B1149 FAILURE CODE [#B1149] Injector Drive Circuit ENG L03 Electrical *1
(Bank2) Short Circuit system
#B1192 FAILURE CODE [#B1192] Oil Pressure Switch ENG L01 Electrical *1
Open Circuit system
#B1198 FAILURE CODE [#B1198] Oil Pressure Low Error ENG L03 Mechanical *1
Alarm system
#B1231 FAILURE CODE [#B1231] Ambient Pressure Sen- ENG L03 Electrical *1
sor Characteristic Error system
#B1262 FAILURE CODE [#B1262] Injector of 1st Cylinder ENG L03 Electrical *1
Short Circuit system
#B1265 FAILURE CODE [#B1265] Injector of 2nd Cylinder ENG L03 Electrical *1
Short Circuit system
#B1268 FAILURE CODE [#B1268] Injector of 3rd Cylinder ENG L03 Electrical *1
Short Circuit system
#B1271 FAILURE CODE [#B1271] Injector of 4th Cylinder ENG L03 Electrical *1
Short Circuit system
#B1341 FAILURE CODE [#B1341] Cam Angle Offset Error ENG L01 Electrical *1
system
#B1404 FAILURE CODE [#B1404] EGR Voltage Low Error ENG L03 Electrical *1
system
#B1405 FAILURE CODE [#B1405] Short Circuit Between ENG L03 Electrical *1
the EGR Motor Coils system
#B1409 FAILURE CODE [#B1409] EGR Feedback Error ENG L03 Electrical *1
system
#B1410 FAILURE CODE [#B1410] EGR High Temperature ENG L03 Electrical *1
Thermistor Error system
#B1411 FAILURE CODE [#B1411] EGR Low Temperature ENG L03 Electrical *1
Thermistor Error system
#B1420 FAILURE CODE [#B1420] Ash Cleaning Request 2 ENG L03 Electrical *1
system
#B1421 FAILURE CODE [#B1421] Stationary Regeneration ENG L03 Electrical *1
Standby system
#B1424 FAILURE CODE [#B1424] Backup Mode ENG L04 Electrical *1
system
#B1426 FAILURE CODE [#B1426] KDPF InterTemperature ENG L03 Electrical *1
High Error (Post-injection) system
#B1427 FAILURE CODE [#B1427] KDPF Inlet Temperature ENG L03 Electrical *1
Sensor Error (Low Voltage) system
#B1428 FAILURE CODE [#B1428] KDPF Inlet Temperature ENG L03 Electrical *1
Sensor Error (High Voltage) system
#B1434 FAILURE CODE [#B1434] KDPF Intermediate Tem- ENG L03 Electrical *1
perature Sens Error(HighVolt) system
#B1435 FAILURE CODE [#B1435] KDPF Intermediate Tem- ENG L03 Electrical *1
perature Sens Error (LowVolt) system

40-100 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING FAILURE CODES TABLE

Failure Applicable Action History cate-

Failure (Displayed on screen) Remarks
code component level gory
#B1436 FAILURE CODE [#B1436] KDPF Inlet Temperature ENG L03 Electrical *1
High Error system
#B1454 FAILURE CODE [#B1454] KDPF High Pressure ENG L03 Electrical *1
Side Sensor Error (Low Voltage) system
#B1455 FAILURE CODE [#B1455] KDPF High Pressure ENG L03 Electrical *1
Side Sens Error (High Volt) system
#B1463 FAILURE CODE [#B1463] Overaccumulation ENG L04 Electrical *1
(Method P) system
#B1467 FAILURE CODE [#B1467] Actuator Drive Circuit 3 ENG L01 Electrical *1
Short to Ground system
#B1469 FAILURE CODE [#B1469] AD Converter Error 1 ENG L04 Electrical *1
system
#B1470 FAILURE CODE [#B1470] AD Converter Error 2 ENG L04 Electrical *1
system
#B1471 FAILURE CODE [#B1471] External Monitoring IC ENG L04 Electrical *1
and CPU Error 1 system
#B1472 FAILURE CODE [#B1472] External Monitoring IC ENG L04 Electrical *1
and CPU Error 2 system
#B1473 FAILURE CODE [#B1473] ROM Error ENG L04 Electrical *1
system
#B1474 FAILURE CODE [#B1474] Shutoff Path Error 1 ENG L04 Electrical *1
system
#B1475 FAILURE CODE [#B1475] Shutoff Path Error 2 ENG L04 Electrical *1
system
#B1476 FAILURE CODE [#B1476] Shutoff Path Error 3 ENG L04 Electrical *1
system
#B1477 FAILURE CODE [#B1477] Shutoff Path Error 4 ENG L04 Electrical *1
system
#B1478 FAILURE CODE [#B1478] Shutoff Path Error 5 ENG L04 Electrical *1
system
#B1479 FAILURE CODE [#B1479] Shutoff Path Error 6 ENG L04 Electrical *1
system
#B1480 FAILURE CODE [#B1480] Shutoff Path Error 7 ENG L04 Electrical *1
system
#B1481 FAILURE CODE [#B1481] Shutoff Path Error 8 ENG L04 Electrical *1
system
#B1482 FAILURE CODE [#B1482] Shutoff Path Error 9 ENG L04 Electrical *1
system
#B1483 FAILURE CODE [#B1483] Shutoff Path Error 10 ENG L04 Electrical *1
system
#B1484 FAILURE CODE [#B1484] Recognition Error of En- ENG L04 Electrical *1
gine Speed system
#B148A FAILURE CODE [#B148A] EGR Stuck Open Valve ENG L03 Electrical *1
Error system
#B1562 FAILURE CODE [#B1562] Charge Switch Open Cir- ENG L01 Electrical *1
cuit system

PC45MR-5, PC55MR-5 40-101

FAILURE CODES TABLE 40 TROUBLESHOOTING

Failure Applicable Action History cate-

Failure (Displayed on screen) Remarks
code component level gory
#B1568 FAILURE CODE [#B1568] Charge Alarm ENG L03 Mechanical *1
system
#B1608 FAILURE CODE [#B1608] Excessive Voltage of ENG L04 Electrical *1
Supply 1 system
#B1609 FAILURE CODE [#B1609] Sensor Supply Voltage ENG L01 Electrical *1
Error 1 system
#B160E FAILURE CODE [#B160E] EEPROM Memory Read ENG L03 Electrical *1
Error system
#B160F FAILURE CODE [#B160F] EEPROM Memory Writ- ENG L03 Electrical *1
ing Error system
#B1613 FAILURE CODE [#B1613] CY146 SPI Communica- ENG L04 Electrical *1
tion Error system
#B1617 FAILURE CODE [#B1617] Insufficient Voltage of ENG L04 Electrical *1
Supply 1 system
#B1618 FAILURE CODE [#B1618] Sensor Supply Voltage ENG L01 Electrical *1
Error 2 system
#B1619 FAILURE CODE [#B1619] Sensor Supply Voltage ENG L01 Electrical *1
Error 3 system
#B1626 FAILURE CODE [#B1626] Actuator Drive Circuit 1 ENG L01 Electrical *1
Short to Ground system
#B1633 FAILURE CODE [#B1633] Actuator Drive Circuit 2 ENG L01 Electrical *1
Short to Ground system
#B1641 FAILURE CODE [#B1641] SCV(MPROP) (Low Side ENG L03 Electrical *1
VB Short) system
#B1642 FAILURE CODE [#B1642] SCV(MPROP) (High ENG L03 Electrical *1
Side GND Short) system
#B1643 FAILURE CODE [#B1643] SCV(MPROP) (Low Side ENG L03 Electrical *1
GND Short) system
#B1645 FAILURE CODE [#B1645] SCV(MPROP) (Pump ENG L03 Electrical *1
Overload Error) system
#B1648 FAILURE CODE [#B1648] Injector of 1st Cylinder ENG L04 Electrical *1
Compensation Value Error system
#B1649 FAILURE CODE [#B1649] Injector of 2nd Cylinder ENG L04 Electrical *1
Compensation Value Error system
#B1650 FAILURE CODE [#B1650] Injector of 3rd Cylinder ENG L04 Electrical *1
Compensation Value Error system
#B1651 FAILURE CODE [#B1651] Injector of 4th Cylinder ENG L04 Electrical *1
Compensation Value Error system
#B1658 FAILURE CODE [#B1658] Power Short of Throttle ENG L03 Electrical *1
Valve Drive H Bridge Out 1 system
#B1659 FAILURE CODE [#B1659] GND Short of Throttle ENG L03 Electrical *1
Valve Drive H Bridge Out 1 system
#B1660 FAILURE CODE [#B1660] O-load on the Drive H ENG L03 Electrical *1
Bridge Cir of Throttle Valve system
#B1661 FAILURE CODE [#B1661] VB P Short of Throttle ENG L03 Electrical *1
Valve Drive H Bridge Out 2 system

40-102 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING FAILURE CODES TABLE

Failure Applicable Action History cate-

Failure (Displayed on screen) Remarks
code component level gory
#B1662 FAILURE CODE [#B1662] GND Short of Throttle ENG L03 Electrical *1
Valve Drive H Bridge Out 2 system
#B1665 FAILURE CODE [#B1665] PLV (Malfunction) ENG L04 Electrical *1
system
#B1666 FAILURE CODE [#B1666] PLV (Number of times of ENG L03 Electrical *1
PLV Valve Opening Error) system
#B1667 FAILURE CODE [#B1667] PLV (Time of PLV Valve ENG L03 Electrical *1
Opening Error) system
#B1668 FAILURE CODE [#B1668] PLV (Non-Performance) ENG L04 Electrical *1
system
#B1669 FAILURE CODE [#B1669] Rail Press Control (Fuel ENG L03 Electrical *1
Temp High in PLV V Open) system
#B1670 FAILURE CODE [#B1670] Rail Press Control ENG L04 Electrical *1
(Pump or Fuel Temp Error) system
#B2228 FAILURE CODE [#B2228] Ambient Pressure Sen- ENG L03 Electrical *1
sor Error (Low Voltage) system
#B2229 FAILURE CODE [#B2229] Ambient Pressure Sen- ENG L03 Electrical *1
sor Error (High Voltage) system
#B242F FAILURE CODE [#B242F] Ash Cleaning Request 1 ENG L03 Electrical *1
system
#B2452 FAILURE CODE [#B2452] KDPF Differential Pres- ENG L03 Electrical *1
sure High Error system
#B2453 FAILURE CODE [#B2453] KDPF Different Press ENG L03 Electrical *1
Sens (Abnormal Learn Value) system
#B2454 FAILURE CODE [#B2454] KDPF Differential Pres- ENG L03 Electrical *1
sure Sens Error (Low Volt) system
#B2455 FAILURE CODE [#B2455] KDPF Differential Pres- ENG L03 Electrical *1
sure Sens Error (High Volt) system
#B2458 FAILURE CODE [#B2458] Defective Regeneration ENG L04 Electrical *1
(StationaryRegene. Failure) system
#B2459 FAILURE CODE [#B2459] Defective Regeneration ENG L04 Electrical *1
(StationaryR Not Performed) system
#B2463 FAILURE CODE [#B2463] Overaccumulation ENG L04 Electrical *1
(Method C) system
#BG10B FAILURE CODE [#BG10B] CAN1 (for EGR): Re- ENG L03 Electrical *1
ception Time Out system
#BG167 FAILURE CODE [#BG167] Immobilizer CAN com- ENG L04 Electrical *1
munication error system
#BG292 FAILURE CODE [#BG292] TSC1 (CAN Message) ENG L01 Electrical *1
Reception Time Out (SA1) system
#BG401 FAILURE CODE [#BG401] EGR ECM Data Error ENG L03 Electrical *1
system
#BG426 FAILURE CODE [#BG426] Immobilizer system error ENG L04 Electrical *1
system
#BH292 FAILURE CODE [#BH292] Y_ECR1 (CAN Mes- ENG L01 Electrical *1
sage) Reception Time Out system

PC45MR-5, PC55MR-5 40-103

FAILURE CODES TABLE 40 TROUBLESHOOTING

Failure Applicable Action History cate-

Failure (Displayed on screen) Remarks
code component level gory
#BH293 FAILURE CODE [#BH293] Y_EC (CAN Message) ENG L01 Electrical *1
Reception Time Out system
#BH303 FAILURE CODE [#BH303] Y_DPFIF (CAN Mes- ENG L01 Electrical *1
sage) Reception Time Out system
#BH401 FAILURE CODE [#BH401] EGR Target Value Out of ENG L03 Electrical *1
Range system

• In this table, failure codes are arranged in alphabetical order.

• Applicable component is the controller which checks the system.
MON: Machine monitor
ENG: Engine controller
MACHINE: Machine controller
KOMTRAX: KOMTRAX terminal
• The failure codes that do not have numbers in the action level columns are not displayed on the standard
screen even when a failure related to them occurs. They are simply recorded in the abnormality record
(electrical system or mechanical system) of the service menu.
• History category means the classification of either electrical system or mechanical system which is used for
storage in the Failure History of the service menu.
*1: For troubleshooting concerning this failure code, see “ Shop Manual Engine 86E-7 to 98E-7 series”.

40-104 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING FAILURE CODE [989L00]

TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF

CODE)
FAILURE CODE [989L00]
Action level Failure code Engine Controller Lock Caution 1
Failure
- 989L00 (Machine monitor system)
Details of
Engine controller lock up is detected (Factor 1).
failure

Action of ma- • None in particular

chine monitor • If cause of failure disappears, machine becomes normal by itself.
Phenomenon
Engine does not start.
on machine
• If the failure code is displayed after replacing the machine monitor, user password needs
Related to be changed back to the previous one.
information • After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

Machine monitor re- This failure may occur due to machine monitor replacement.
1
placed

PC45MR-5, PC55MR-5 40-105

FAILURE CODE [989M00] 40 TROUBLESHOOTING

FAILURE CODE [989M00]

Action level Failure code Engine Controller Lock Caution 2
Failure
- 989M00 (Machine monitor system)
Detail of fail-
Machine monitor detects abnormal state of engine controller lock (factor 2).
ure

Action of ma- • None in particular

chine monitor • If cause of failure disappears, machine becomes normal by itself.
Phenomenon
Engine does not start.
on machine
• If this failure code is displayed after replacing the machine monitor, user password needs
Related to be changed back to the previous one.
information • After completion of repair, check if the failure code is cleared by the following procedure.
Procedure: Turn the starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

Machine monitor re- This failure may occur due to machine monitor replacement.
1
placed
If this failure code appears even when machine monitor is not replaced, failure in
Defective machine moni-
2 machine monitor may occur. (Because this is an internal defect, troubleshooting
tor
cannot be performed.)

40-106 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING FAILURE CODE [989N00]

FAILURE CODE [989N00]

Action level Failure code Engine Controller Lock Caution 3
Failure
- 989N00 (Machine monitor system)
Detail of fail-
Machine monitor detects engine controller lock (Factor 3).
ure

Action of ma- • Tries automatic recovery.

chine monitor • If cause of failure disappears, machine becomes normal by itself.
Phenomenon
on machine
Related After completion of repair, check if the failure code is cleared by the following procedure.
information Procedure: It cannot be reproduced since machine has become normal by itself.

No. Cause Procedure, measuring location, criteria and remarks

Defective engine control- If this repeatedly occurs, engine controller may be defective. (In case of an internal
1
ler defect, troubleshooting is impossible as an assembly. Replace whole assembly.)

PC45MR-5, PC55MR-5 40-107

FAILURE CODE [AQ20R1] 40 TROUBLESHOOTING

FAILURE CODE [AQ20R1]

Action level Failure code KCSF Manual Stationary Regeneration Request
Failure
L01 AQ20R1 (Machine controller system)
The "Manual Stationary Regeneration Request" prompts operator to forcibly perform "Manual Sta-
Details of tionary Regeneration", which is more effective to remove soot, because soot accumulation in the
failure KCSF of KDPF has exceeded the level for automatic regeneration.
Soot accumulation reaches level 4 or 5.
Action of
Normal control
controller
Phenomenon
None in particular
on machine

NOTICE
• If this failure code [AQ20R1] is displayed, perform manual stationary regeneration.
• This failure code is displayed during Manual Stationary Regeneration, but it is nor-
mal.
k Since KDOC and KDPF are heated to 600 °C or above, be careful not to get burn injury.
Related
information • Time required for manual stationary regeneration is approximately 30 minutes.
• If soot accumulation is level 8: Manual stationary regeneration cannot be performed.
• If another failure code is displayed (including when manual stationary regeneration is in
progress), perform troubleshooting these first.
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.

40-108 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING FAILURE CODE [B@BCNS]

FAILURE CODE [B@BCNS]

Action level Failure code Engine Water Overheat
Failure
L02 B@BCNS (Machine controller system)
Details of Machine controller detects engine coolant temperature overheat by the engine coolant temperature
failure information from engine controller while engine is running.

Action of • Lights up engine coolant temperature monitor in red on machine monitor.

controller • Engine power deration
Phenomenon • If machine is used as it is, engine may be seized.
on machine • Engine power deration
• Signal voltage of coolant temperature sensor is input to engine controller, and then it is
transmitted from machine controller to machine monitor through CAN communication sys-
tem.
Related
• Engine coolant temperature can be checked with monitoring function (Code: 04107 En-
information gine coolant temperature)
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Start engine.

No. Cause Procedure, measuring location, criteria and remarks

Overheat of engine cool- Engine coolant may overheat. Check coolant temperature and remove cause of
1 ant (when system works failure if engine coolant overheats.
properly)
Defective engine coolant If failure code is still displayed after above checks on cause 1, engine coolant tem-
2 temperature sensor sys- perature sensor system may be defective. Perform troubleshooting for failure codes
tem [#B0117] and [#B0118].

PC45MR-5, PC55MR-5 40-109

FAILURE CODE [D19JKZ] 40 TROUBLESHOOTING

FAILURE CODE [D19JKZ]

Action level Failure code Personal Code Relay Open Circuit or Short Circuit
Failure
L03 D19JKZ (Machine monitor system)
Detail of fail-
Open error or short circuit occurs in primary (coil) circuit of personal code relay.
ure
• None in particular (when open error occurred)
• Stops driving personal code relay (when short circuit occurred).
Action of ma- • If cause of failure disappears, machine becomes normal by itself (when open error occur-
chine monitor red).
• Even if cause of failure disappears, machine does not become normal until starting switch
is turned to OFF position (when short circuit occurred).
Phenomenon
No
on machine
• This failure code is displayed only when engine lock function is enabled.
• After repairing, check if the failure code is cleared by the following procedure.
Related Procedure: Turn starting switch to ON position (when open circuit occurred). Failure code
information cannot be reproduced on the machine (when short circuit occurred).
• Troubleshooting for this failure code covers circuits from fuse No. 3 in fuse box FB1
through primary (coil) circuit of personal code relay R06 to machine monitor.

No. Cause Procedure, measuring location, criteria and remarks

1 Defective fuse If fuse FB1 (No.3) is blown out, circuit probably has ground fault, etc.
1. Turn the starting switch to OFF position.
2. Disconnect relay R06, and connect T-adapter to male side.
Resistance Between R06 (male) (1) and (2) 80 to 200 Ω
Defective personal code
2 1. Turn the starting switch to OFF position.
relay
2. Replace relay R06 with light relay R04.
3. Turn the starting switch to ON position.
If this failure code disappears, original personal code relay R06 is defective.
1. Turn the starting switch to OFF position.
2. Remove fuse No.3 in fuse box FB1
Open or short circuit or
3 ground fault in wiring har- 3. Disconnect connectors F15, and connect T-adapter to female side of F15.
ness Between FB1-3 and F15 (female) (4) 80 to 200 Ω
Resistance
Between ground and FB1-3 or F15 (female) (4) Min. 1 MΩ
If no failure is found by check on cause 3, this check is not required.
1. Turn the starting switch to OFF position.
2. Remove fuse No.3 in fuse box FB1
Open circuit in wiring har- 3.
4 Disconnect connector F15 and relay R06, and connect T-adapters to each
ness
female side.
Between FB1-3 and R06 (female) (1) Max. 1 Ω
Resistance
Between R06 (female) (2) and F15 (female) (4) Max. 1 Ω

40-110 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING FAILURE CODE [D19JKZ]

No. Cause Procedure, measuring location, criteria and remarks

If no failure is found by check on cause 3, this check is not required.
1. Turn the starting switch to OFF position.
2. Remove fuse No.3 in fuse box FB1
Ground fault in wiring 3. Disconnect connectors F15 and R06, and connect T-adapter to either fe-
5
harness male side.
Between ground and FB1-3 or R06 (female) (1) Min. 1 MΩ
Resistance Between ground and R06 (female) (2) or F15 (female)
Min. 1 MΩ
(4)
1. Turn the starting switch to OFF position.
2. Remove fuse No.3 in fuse box FB1
3. Disconnect connector F15 and relay R06, and connect T-adapter to female
Short circuit in wiring har-
6 side of connector F15.
ness
Check it by using multimeter in continuity mode.
No continui-
Continuity Between F15 (female) (4) and each pin other than (4)
ty
Defective machine moni- If no failure is found by above checks, machine monitor is defective. (Since this is
7
tor an internal defect, troubleshooting cannot be performed.)

PC45MR-5, PC55MR-5 40-111

FAILURE CODE [D19JKZ] 40 TROUBLESHOOTING

Circuit diagram related to personal code relay

40-112 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING FAILURE CODE [D811MC]

FAILURE CODE [D811MC]

Action level Failure code KOMTRAX Malfunction
Failure
- D811MC (KOMTRAX system)
Detail of fail-
KOMTRAX Malfunction
ure
Action of
controller
Phenomenon
KOMTRAX system does not operate normally.
on machine
Related After completion of repair, check if the failure code is cleared by the following procedure.
information Procedure: Turn the starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

Defective KOMTRAX (In case of an internal defect, troubleshooting is impossible
1 KOMTRAX Error
as an assembly. Replace whole assembly.)

PC45MR-5, PC55MR-5 40-113

FAILURE CODE [D862KA] 40 TROUBLESHOOTING

FAILURE CODE [D862KA]

Action level Failure code GPS Antenna Open Circuit
Failure
- D862KA (KOMTRAX system)
Details of
Open circuit occurs in GPS antenna circuit.
failure
Action of • None in particular
controller • If cause of failure disappears, machine becomes normal by itself.
Phenomenon
GPS positioning system does not work.
on machine
Related After repairing, check if the failure code is cleared by the following procedure.
information Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

Defective GPS antenna GPS antenna may be defective, or antenna cable may have open or short circuit,
1
or antenna cable or poor contact at terminal area (GPS).

Configuration diagram of GPS system

40-114 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING FAILURE CODE [D8ALKA]

FAILURE CODE [D8ALKA]

Action level Failure code System Operating Lamp Open Circuit (KOMTRAX)
Failure
- D8ALKA (KOMTRAX system)
KOMTRAX terminal determines that system operating lamp circuit is open because voltage of out-
Detail of fail- put circuit remains at approximately. 5 V or less for approximately 3 seconds after starting switch is
ure turned to ON position, during which KOMTRAX terminal outputs no current to system operating
lamp.
Action of
None in particular
controller
Phenomenon While system operating lamp is lit, battery disconnect switch must not be turned to OFF position.
on machine Turning battery disconnect switch to OFF position may destroy data stored in KOMTRAX memory.

• This failure code is displayed only when the battery disconnect switch is set effectively.
• After completion of repair, check if the failure code is cleared by the following procedure.
Procedure: Turn the starting switch to ON position.
Related • Although KOMTRAX is not able to light up system operating lamp, no trouble will result
information unless battery disconnect switch is turned to OFF position.
• When controller lights up system operating lamp, output circuit voltage is at low level.
• Since no controller drives system operating lamp for approximately 3 seconds after start-
ing switch is turned to ON position, open circuit can be detected.

No. Cause Procedure, measuring location, criteria and remarks

1 Defective fuse If fuse No.12 in fuse box FB1 is blown out, circuit probably has ground fault, etc.
1. Turn the starting switch to OFF position.
Open circuit in wiring har- 2. Remove fuse No.12 in fuse box FB1
ness (wire breakage or 3. Disconnect connector CK01 and connect T-adapter to female side.
2
defective contact of con-
nector) Between FB1-12 and M22 (female) (1) Max. 1 Ω
Resistance
Between CK01 (female) (15) and M22 (female) (2) Max. 1 Ω
If no failure is found by preceding checks, KOMTRAX terminal is defective. (In case
Defective KOMTRAX ter-
3 of an internal defect, troubleshooting is impossible as an assembly. Replace whole
minal
assembly.)

PC45MR-5, PC55MR-5 40-115

FAILURE CODE [D8ALKA] 40 TROUBLESHOOTING

Circuit diagram related to system operating lamp

40-116 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING FAILURE CODE [D8ALKB]

FAILURE CODE [D8ALKB]

Action level Failure code System Operating Lamp Short Circuit (KOMTRAX)
Failure
- D8ALKB (KOMTRAX system)
KOMTRAX terminal determines that system operating lamp circuit shorts because voltage of output
Detail of fail-
circuit does not become low level while KOMTRAX terminal outputs current to system operating
ure
lamp.
Action of
None in particular
controller
Phenomenon While system operating lamp is lit, battery disconnect switch must not be turned to OFF position.
on machine Turning battery disconnect switch to OFF position may destroy data stored in KOMTRAX memory.

• This failure code is displayed only when the battery disconnect switch is set effectively.
• After completion of repair, check if the failure code is cleared by the following procedure.
Related Procedure: Turn the starting switch to ON position.
information • Although KOMTRAX is not able to light up system operating lamp, no trouble will result
unless battery disconnect switch is turned to OFF position.
• When controller lights up system operating lamp, output circuit voltage is at low level.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Remove fuse No.12 in fuse box FB1
Short circuit in wiring har-
1 3. Disconnect connectors F15, CP02, CK01, and M22. Connect T-adapter to
ness
female side of M22.
Resistance Between M22 (female) (1) and (2) Min. 1 MΩ
If no failure is found by preceding checks, KOMTRAX terminal is defective. (In case
Defective KOMTRAX ter-
2 of an internal defect, troubleshooting is impossible as an assembly. Replace whole
minal
assembly.)

PC45MR-5, PC55MR-5 40-117

FAILURE CODE [D8ALKB] 40 TROUBLESHOOTING

Circuit diagram related to system operating lamp

40-118 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING FAILURE CODE [D8AQKR]

FAILURE CODE [D8AQKR]

Action level Failure code CAN 2 Defective Communication (KOMTRAX)
Failure
― D8AQKR (Detected by machine monitor.) (Machine monitor system)
Detail of fail-
Machine monitor does not recognize KOMTRAX over CAN communication-2 line (KOMNET/c).
ure
Action of ma-
None
chine monitor
Phenomenon
None
on machine
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.
• Start of CAN communication is recognized by each controller when ACC signal of starting
switch is received.
• 2 different failure codes, [DBHQKR], and [D8AQKR], are used for defective CAN commu-
Related nication by CAN2 when it is detected by machine monitor. When all of these 2 failure co-
information des are displayed, ground fault, short circuit or hot short in wiring harness (CAN communi-
cation circuit) can be suspected.
• Since each controller and machine monitor are connected directly to battery, they are sup-
plied with power even after starting switch is turned to OFF position.
• Since signal of active CAN communication line is pulse voltage, it cannot be measured by
using multimeter.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect fusible link M09 and connect T-adapter to male side.
1 Defective fusible link
Resistance Between M09 (male) (1) and (2) Max. 1 Ω
If fusible link is blown, circuit may have ground fault.
1. Turn starting switch to OFF position.
2 Defective fuse 2. Remove fuse No.13 in fuse box FB1.
If fuse is blown, circuit probably has ground fault.
Defective power supply Perform troubleshooting for “KOMTRAX SYSTEM DOES NOT OPERATE NOR-
3
to KOMTRAX terminal MALLY” of E mode.
Defective CAN communi- Perform checks on causes 5 to 10 in troubleshooting for failure code [DBHQKR].
4
cation 2 system
Defective KOMTRAX ter- If no failure is found by preceding checks, KOMTRAX terminal is defective. (Since
5
minal this is an internal defect, troubleshooting cannot be performed.)
Defective machine moni- If no failure is found by above checks, machine monitor is defective. (Since this is
6
tor an internal defect, troubleshooting cannot be performed.)

PC45MR-5, PC55MR-5 40-119

FAILURE CODE [D8AQKR] 40 TROUBLESHOOTING

Circuit diagram related to CAN2 communication

40-120 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING FAILURE CODE [DAF0KT]

FAILURE CODE [DAF0KT]

Action level Failure code EEPROM Error (Monitor)
Failure
L03 DAF0KT (Machine monitor system)
Detail of fail-
Data cannot be written to or read from non-volatile memory of machine monitor.
ure
Action of
None in particular
controller
Phenomenon
Reading of service meter and other set values are changed.
on machine
Related After repair is completed, check if the failure code is cleared by the following procedure.
information Procedure: Turn the starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

Defective machine moni- Defective machine monitor (Because this is an internal defect, troubleshooting can-
1
tor not be performed.)

PC45MR-5, PC55MR-5 40-121

FAILURE CODE [DAF0MB] 40 TROUBLESHOOTING

FAILURE CODE [DAF0MB]

Action level Failure code Monitor ROM Abnormality
Failure
- DAF0MB (Machine monitor system)
Detail of fail-
Machine monitor program is rewritten (program error).
ure
Action of Even if cause of failure is eliminated, machine does not become normal until starting switch is
controller turned to OFF position.

Phenomenon • Machine monitor display is unreliable.

on machine • It can neither transmit the data to controllers nor receive the data from them.
Related After completion of repair, check if the failure code is cleared by the following procedure.
information Procedure: Turn the starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

Defective machine moni- Defective machine monitor (Because this is an internal defect, troubleshooting can-
1
tor not be performed.)

40-122 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING FAILURE CODE [DAF0MC]

FAILURE CODE [DAF0MC]

Action level Failure code Monitor Malfunction
Failure
- DAF0MC (Machine monitor system)
Detail of fail-
Malfunction of machine monitor
ure
Action of
controller
Phenomenon • Machine monitor display is unreliable.
on machine • It can neither transmit the data to controllers nor receive the data from them.
Related After completion of repair, check if the failure code is cleared by the following procedure.
information Procedure: Turn the starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

Defective machine moni- Defective machine monitor (Because this is an internal defect, troubleshooting can-
1
tor not be performed.)

PC45MR-5, PC55MR-5 40-123

FAILURE CODE [DAF3KK] 40 TROUBLESHOOTING

FAILURE CODE [DAF3KK]

Action level Failure code Main Power Voltage Low Error (Monitor)
Failure
- DAF3KK (Machine monitor system)
Detail of fail-
Continuous power supply voltage of monitor controller drops below 9.8 V.
ure
Action of • Prohibits writing to memory.
controller • If cause of failure disappears, machine becomes normal by itself.
Phenomenon • Monitor screen may stay blank.
on machine • Since writing to non-volatile memory is prohibited, reliability of displayed information is low.
• Machine monitor does not display any failure code.

Related • Operating voltage cannot be measured at monitor controller connector since T-adapter for
machine monitor connector is socket-type box.
information
• After repair is completed, check if the failure code is cleared by the following procedure.
Procedure: Turn the starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

1 Defective fusible link If fusible link M09 is burnt out, circuit probably has ground fault. (See cause 4.)
If fuse FB1 (No.13) is blown out, circuit probably has ground fault, etc. (See cause
2 Defective fuse
4.)
1. Turn the starting switch to OFF position.
2. Disconnect the battery ground, or turn the battery disconnect switch to OFF
position.
3. Disconnect connector F15, and connect T-adapter to female side.
4. Connect the battery ground, or turn the battery disconnect switch to ON
position.
5. Turn the starting switch to ON position.
Between F15 (1) and (2) 10 to 15 V
Open circuit in wiring har- Voltage
Between F15 (6) and (7) 10 to 15 V
3 ness (wire breakage or
defective contact) REMARK
Replace fuse FB1 (No.13) and fusible link M09 if they are burnt out.
1. Turn the starting switch to OFF position.
2. Turn the battery disconnect switch to OFF position.
3. Disconnect connector F15, and connect T-adapter to female side.
Between battery (+) and each of F15 (1) and (6) Max. 1 Ω
Resistance Check the ground terminal T01 for looseness and rust.
Max. 1 Ω
Between ground and each of F15 (2) and (7)
1. Turn the starting switch to OFF position.
Ground fault in wiring 2. Disconnect fuse FB1 (No.13) and connector F15, and connect T-adapters
4 harness (contact with to female side.
ground circuit)
Between ground and each of fuse FB1 (No.13), F15
Resistance Min. 1 MΩ
(1), and (6)
Defective machine moni- If no failure is found by above checks, machine monitor is defective. (Since this is
5
tor an internal defect, troubleshooting cannot be performed.)

40-124 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING FAILURE CODE [DAF3KK]

Circuit diagram related to machine monitor power supply

PC45MR-5, PC55MR-5 40-125

FAILURE CODE [DAF9KQ] 40 TROUBLESHOOTING

FAILURE CODE [DAF9KQ]

Action level Failure code Model Selection Signal Mismatch (Monitor)
Failure
L03 DAF9KQ (Machine monitor system)

Detail of fail- Machine model registered in machine monitor and machine controller differs.
ure (Machine monitor or machine controller of wrong part number is installed for replacement.)
Action of
controller
Phenomenon
Machine does not operate normally.
on machine
Signal state (ON/OFF) of model selection signal can be checked with monitoring function. (Code:
02201)
• PC45MR-5
Model selection signal 1: OFF
Model selection signal 2: ON
• PC55MR-5
Related Model selection signal 1: ON
information Model selection signal 2: OFF
• Assembly part number of machine controller program can be checked with monitoring
function. (Code: 20294)
• Assembly part number of machine monitor program can be checked with monitoring func-
tion. (Code: 20227)
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

Defective machine moni- Display assembly part number by monitoring function, and check that displayed
1
tor number is same as the one in the Parts Book.
Defective machine con- Display assembly part No. with monitoring function and check if it is same as part
2
troller No. in the parts book.

40-126 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING FAILURE CODE [DAFGMC]

FAILURE CODE [DAFGMC]

Action level Failure code GPS Module Malfunction
Failure
- DAFGMC (KOMTRAX system)
Details of No position data is sent from GPS module (KOMTRAX terminal) to KOMTRAX communication mo-
failure dem more than 50 seconds since the startup of KOMTRAX.

Action of • None in particular

controller • If cause of failure disappears, machine becomes normal by itself.
Phenomenon
on machine
After repairing, check if the failure code is cleared by the following procedure.
Related
Procedure: Turn starting switch to ON position. (Wait for more than 50 seconds after the switch is
information
turned ON.)

No. Cause Procedure, measuring location, criteria and remarks

Defective KOMTRAX ter- GPS module of KOMTRAX terminal may be defective. (Because this is an internal
1
minal defect, troubleshooting cannot be performed.)

PC45MR-5, PC55MR-5 40-127

FAILURE CODE [DAFLKA] 40 TROUBLESHOOTING

FAILURE CODE [DAFLKA]

Action level Failure code System Operating Lamp Open Circuit (Monitor)
Failure
- DAFLKA (Machine monitor system)
Machine monitor determines that system operating lamp circuit is open because voltage of output
Detail of fail-
circuit remains at approximately. 5 V or less for approximately 3 seconds after starting switch is
ure
turned to ON position, during which machine monitor outputs no current to system operating lamp.
Action of
None in particular
controller

Phenomenon While system operating lamp is lit, battery disconnect switch must not be turned to OFF position.
Turning battery disconnect switch to OFF position may destroy data stored in machine monitor
on machine memory.
• This failure code is displayed only when the battery disconnect switch is set effectively.
• After completion of repair, check if the failure code is cleared by the following procedure.
Procedure: Turn the starting switch to ON position.
Related • Although machine monitor is not able to light up system operating lamp, no trouble will re-
information sult unless battery disconnect switch is turned to OFF position.
• When controller lights up system operating lamp, output circuit voltage is at low level.
• Since no controller drives system operating lamp for approximately 3 seconds after start-
ing switch is turned to ON position, open circuit can be detected.

No. Cause Procedure, measuring location, criteria and remarks

1 Defective fuse If fuse No.12 in fuse box FB1 is blown out, circuit probably has ground fault, etc.
1. Turn the starting switch to OFF position.
Open circuit in wiring har- 2. Remove fuse No.12 in fuse box FB1
ness (wire breakage or 3. Disconnect connector F15 and connect T-adapter to female side.
2
defective contact of con-
nector) Between FB1-12 and M22 (female) (1) Max. 1 Ω
Resistance
Between F15 (female) (10) and M22 (female) (2) Max. 1 Ω
Defective machine moni- If no failure is found by above checks, machine monitor is defective. (Since this is
3
tor an internal defect, troubleshooting cannot be performed.)

40-128 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING FAILURE CODE [DAFLKA]

Circuit diagram related to system operating lamp

PC45MR-5, PC55MR-5 40-129

FAILURE CODE [DAFLKB] 40 TROUBLESHOOTING

FAILURE CODE [DAFLKB]

Action level Failure code System Operating Lamp Short Circuit (Monitor)
Failure
- DAFLKB (Machine monitor system)
Detail of fail- Machine monitor determines that system operating lamp circuit shorts because voltage of output cir-
ure cuit does not become low level while machine monitor outputs current to system operating lamp.
Action of
None in particular
controller

Phenomenon While system operating lamp is lit, battery disconnect switch must not be turned to OFF position.
Turning battery disconnect switch to OFF position may destroy data stored in machine monitor
on machine memory.
• This failure code is displayed only when the battery disconnect switch is set effectively.
• After completion of repair, check if the failure code is cleared by the following procedure.
Related Procedure: Turn the starting switch to ON position.
information • Although machine monitor is not able to light up system operating lamp, no trouble will re-
sult unless battery disconnect switch is turned to OFF position.
• When controller lights up system operating lamp, output circuit voltage is at low level.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Remove fuse No.12 in fuse box FB1
Short circuit in wiring har-
1 3. Disconnect connectors F15, CP02, CK01, and M22. Connect T-adapter to
ness
female side of M22.
Resistance Between M22 (female) (1) and (2) Min. 1 MΩ
Defective machine moni- If no failure is found by above checks, machine monitor is defective. (Since this is
2
tor an internal defect, troubleshooting cannot be performed.)

40-130 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING FAILURE CODE [DAFLKB]

Circuit diagram related to system operating lamp

PC45MR-5, PC55MR-5 40-131

FAILURE CODE [DAFQKR] 40 TROUBLESHOOTING

FAILURE CODE [DAFQKR]

Action level Failure code CAN 2 Defective Communication (Monitor)
Failure
- DAFQKR (KOMTRAX system)
Detail of fail-
KOMTRAX terminal does not recognize machine monitor through CAN communication 2 line.
ure
Action of
controller
Phenomenon
System may not operate normally.
on machine
• After completion of repair, check if the failure code is cleared by the following procedure.
Procedure: Turn the starting switch to ON position.
• ACC signal of starting switch is the command to start CAN communication for each con-
troller.

Related • Failure code is transmitted to and displayed on machine monitor by CAN communication.
If CAN communication with machine monitor fails, failure code [DAFQKR] is not displayed
information on machine monitor. It can be observed only through KOMTRAX system.
• Since each controller and machine monitor are connected directly to the battery, they are
supplied with power even after the starting switch is turned to OFF position.
• Since signal of active CAN communication line is pulse voltage, it cannot be measured by
using multimeter.

No. Cause Procedure, measuring location, criteria and remarks

Defective power supply Perform troubleshooting for “When starting switch is turned to ON position, ma-
1
to machine monitor chine monitor displays nothing” of E mode.
Defective CAN communi- Perform checks on cause 4 and subsequent causes in troubleshooting for failure
2
cation code [DBHQKR].

40-132 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING FAILURE CODE [DB2QKR]

FAILURE CODE [DB2QKR]

Action level Failure code CAN 2 Defective Communication (Engine Controller)
Failure
L03 DB2QKR (Machine controller system)
Detail of fail-
Machine controller cannot recognize engine controller on CAN2 communication line (engine only).
ure
Action of
Retains information at time of occurrence of failure.
controller
Information to be obtained from engine controller is not displayed and special functions that need
Phenomenon
information do not work. Or update of received data is stopped.
on machine
(Failure codes and monitoring codes sent from the engine controller, etc.)
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.
• Start of CAN communication is recognized by each controller when ACC signal of starting
Related switch is received.
information • Since each controller and machine monitor are connected directly to battery, they are sup-
plied with power even after starting switch is turned to OFF position.
• Since signal of active CAN communication line is pulse voltage, it cannot be measured by
using multimeter.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
1 Defective fuse 2. Remove fuses No.10 and No.14 from fuse box FB1
If fuse is blown out, the engine controller probably has short circuit.
Check ground terminal T03 for looseness and rust.
1. Turn the starting switch to OFF position.
2. Disconnect the battery ground, or turn the battery disconnect switch to OFF
position.
3. Disconnect connector CE1, and connect T-adapter to female side.
Defective power supply 4. Connect the battery ground, or turn the battery disconnect switch to ON
2
to engine controller position.
5. Turn the starting switch to ON position.
Between CE1 (female) (1) and (2) 10 to 15 V
Voltage Between CE1 (female) (3) and (4) 10 to 15 V
Between CE1 (female) (5) and (6) 10 to 15 V
1. Turn the starting switch to OFF position.
Defective CAN terminat- 2. Disconnect connectors CP01, and CE1, and connect T-adapter to male
ing resistor side.
3
(internal open or short
Between CP01 (male) (15) and (45) 120±12 Ω
circuit) Resistance
Between CE1 (male) (53) and (75) 120±12 Ω

PC45MR-5, PC55MR-5 40-133

FAILURE CODE [DB2QKR] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

CAN communication line
REMARK
CAN terminating resistor of 120 Ω are located in machine controller and engine
controller. That is, CAN terminating resistors of 120 Ω are connected in parallel.
1. Turn the starting switch to OFF position.
2. Disconnect the battery ground, or turn the battery disconnect switch to
OFF position.
Open or short circuit in
4 3. Disconnect related connectors, and connect T-adapter to connector to be
wiring harness
measured.
REMARK
If short circuit is found (resistance between 2 terminals is below 1 Ω), disconnect all
CAN communication connectors of every controller, and check whether short circuit
occurs between wiring harnesses or inside controller.
Approx.
Resistance Between CP01 (female) (45) and (64)
120 Ω
ACC signal of starting switch (start of CAN communication is not recognized)
1. Turn the starting switch to OFF position.
2. Disconnect the battery ground, or turn the battery disconnect switch to
OFF position.
3. Disconnect connectors to be measured and insert T-adapters.
4. Connect the battery ground, or turn the battery disconnect switch to ON
position.
5. Turn the starting switch to ON position.
Open circuit in wiring har- Between CP01 (17) and (2) 10 to 15 V
ness Voltage
5 Between CE1 (88) and (2) 10 to 15 V
(wire breakage or defec-
tive contact of connector) If no failure is found by check on cause 4, this check is not required.
1. Turn the starting switch to OFF position.
2. Disconnect the battery ground, or turn the battery disconnect switch to
OFF position.
3. Disconnect related connectors, and connect T-adapter to each female side
connector to be measured.
Between CP01 (female) (45) and CE1 (female) (75) Max. 1 Ω
Resistance Between CP01 (female) (64) and CE1 (female) (53) Max. 1 Ω
Between CP01 (female) (15) and (34) Max. 1 Ω
If no failure is found by check on cause 4 (no open circuit), measure resistance at
any one place.
1. Turn the starting switch to OFF position.
2. Disconnect the battery ground, or turn the battery disconnect switch to
Ground fault in wiring OFF position.
harness
6 3. Disconnect related connectors, and connect T-adapter to each female side
(contact with ground cir- connector to be measured.
cuit)
Between ground and any of CP01 (female) (45), and
Min. 1 MΩ
CE1 (female) (75)
Resistance
Between ground and any of CP01 (female) (64), and
Min. 1 MΩ
CE1 (female) (53)

40-134 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING FAILURE CODE [DB2QKR]

No. Cause Procedure, measuring location, criteria and remarks

If no failure is found by check on cause 4 (no open circuit), measure resistance at
any one place in each case.
1. Turn the starting switch to OFF position.
2. Disconnect the battery ground, or turn the battery disconnect switch to
OFF position.
Short circuit or hot short 3. Insert T-adapter into connector to measure.
7 circuit in wiring harness 4. Connect the battery ground, or turn the battery disconnect switch to ON
(contact with 12 V circuit) position.
5. Turn the starting switch to ON position.
Between ground and any of CP01 (female) (45), and
1 to 4 V
CE1 (female) (75)
Voltage
Between ground and any of CP01 (female) (64), and
1 to 4 V
CE1 (female) (53)
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
8
ler an internal defect, troubleshooting cannot be performed.)
Defective machine moni- If no failure is found by above checks, machine monitor is defective. (Since this is
9
tor an internal defect, troubleshooting cannot be performed.)
Defective machine con- If no failure is found by preceding checks, work equipment controller is defective.
10
troller (Since this is an internal defect, troubleshooting cannot be performed.)

PC45MR-5, PC55MR-5 40-135

FAILURE CODE [DB2QKR] 40 TROUBLESHOOTING

Circuit diagram related to CAN2 communication

40-136 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING FAILURE CODE [DBH0MC]

FAILURE CODE [DBH0MC]

Action level Failure code Pump Controller Malfunction
Failure
― DBH0MC (Machine controller system)
Detail of fail-
Malfunction of machine controller operation
ure
Action of
No
controller
Phenomenon
Machine controller does not operate normally.
on machine
Related After repairing, check if the failure code is cleared by the following procedure.
information Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

Mulfunction of machine If machine operates normally, it is not needed to replace.
1
controller

PC45MR-5, PC55MR-5 40-137

FAILURE CODE [DBH2KK] 40 TROUBLESHOOTING

FAILURE CODE [DBH2KK]

Action level Failure code Machine Controller Solenoid Power Voltage Low Error
Failure
L03 DBH2KK (Machine controller system)
Detail of fail-
Power supply voltage of controller for driving solenoids is below below. 8 V.
ure
• Stops detection of failures (open circuit and short circuit) in all solenoid systems while this
Action of
failure code is active.
controller
• If cause of failure disappears, machine becomes normal by itself.
Phenomenon No solenoid valve is energized properly, so machine does not work properly.
on machine (Work equipment, swing, and travel systems do not work.)
• As T-adapter for machine controller connector is “socket-type box”, operating voltage can-
Related not be measured at machine controller connector.
information • After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

1 Defective fusible link If fusible link M05 is blown out, circuit probably has ground fault, etc. (see cause 6)
If fuse No.2 in fuse box FB1 is blown out, circuit probably has ground fault, etc.
2 Defective fuse
(see cause 6)
1. Turn starting switch to OFF position.
3 Improper battery voltage 2. After measuring voltage, measure it again when starting engine.
Voltage Between battery (+) and ground 10 to 15 V
1. Turn the starting switch to OFF position.
2. Disconnect ground cable of battery or turn the battery disconnect switch to
OFF position.
3. Disconnect connector CP02, and connect T-adapter to female side.
4 Defective wiring harness 4. Connect ground cable of battery or turn the battery disconnect switch to ON
position.
5. Turn the starting switch to ON position.
Between ground and each of CP02 (female) (116),
Voltage 10 to 15 V
(118) and (121)

40-138 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING FAILURE CODE [DBH2KK]

No. Cause Procedure, measuring location, criteria and remarks

If no failure is found by check on cause 4, this check is not required.
If fusible link or fuse is blown, replace it in advance.
1. Turn the starting switch to OFF position.
2. Disconnect ground cable of battery or turn the battery disconnect switch to
OFF position.
3. Disconnect connector CP02, and connect T-adapter to female side.
Between battery (+) terminal and each of CP02 (fe-
Open circuit in wiring har- Resistance male) (116), (118), and (121) Max. 1 Ω
5
ness
If no failure is found by preceding checks, this check is not required.
Furthermore, disconnect connector M05, and connect T-adapter to male side.
Between FB1 (2) and each of CP02 (female) (116),
Max. 1 Ω
(118), and (121)

Resistance Between FB1 (1A) and TF3 Max. 1 Ω

Between TF1 and M05 (male) (1) Max. 1 Ω
Between M05 (male) (2) and battery (+) terminal Max. 1 Ω
If no failure is found by check on cause 4, this check is not required.
1. Turn the starting switch to OFF position.
2. Disconnect ground cable of battery or turn the battery disconnect switch to
OFF position.
Ground fault in wiring 3. Disconnect fuse FB1 (2) and connectors M05 and CP02, and connect T-
harness adapter to female side of CP02 and male side of M05.
6
(Contact with ground cir- Between ground and each of CP02 (female) (116),
cuit) Min. 1 MΩ
(118), (121), or FB1 (2)

Resistance Between ground and FB1 (1A) or TF3 Min. 1 MΩ

Between ground and TF1 or M05 (male) (1) Min. 1 MΩ
Between M05 (male) (2) and ground Min. 1 MΩ
Defective machine con- If no failure is found by preceding checks, work equipment controller is defective.
7
troller (Since this is an internal defect, troubleshooting cannot be performed.)

PC45MR-5, PC55MR-5 40-139

FAILURE CODE [DBH2KK] 40 TROUBLESHOOTING

Circuit diagram related to machine controller solenoid power supply

40-140 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING FAILURE CODE [DBH5KP]

FAILURE CODE [DBH5KP]

Action level Failure code 5 V Sensor 1 Power Voltage Low Error
Failure
- DBH5KP (Machine controller system)
Detail of fail-
Voltage of 5 V sensor power supply output 1 circuit is below 2.5 V or above 6.0 V.
ure
• Stops output of power from 5 V sensor power supply output 1.
Action of
• Even if cause of failure disappears, machine does not become normal until starting switch
controller
is turned to OFF position.
• Signal of pressure sensor is not input properly.
• The error code for the pressure sensor is displayed at the same time.
Phenomenon
• Travel and work equipment speeds are slow.
on machine
• Auto-decelerator function remains activated or fine control performance of work equipment
is poor.
Related After completion of repair, check if the failure code is cleared by the following procedure.
information Procedure: Turn the starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect connectors of the following sensors one by one and turn the
starting switch to ON position each time.
REMARK
• If this failure code goes out, disconnected sensor is defective.
Defective pressure sen- • Since connector is disconnected, other failure codes are displayed. Ig-
1 sor nore all of displayed failure codes other than this one.
(internal short circuit) 3. Each time troubleshooting is finished, return to step 1.
Travel pressure sensor P02
Swing parking brake lock pressure sensor P03
Connector
Service pressure sensor 1 (dummy) P11
Service pressure sensor 2 (dummy) P12
Measure voltage before controller stops output of power.
1. Turn the starting switch to OFF position.
Hot short circuit in wiring
harness 2. Disconnect connectors P02 to P03, P11, and P12.
2 3.
(Contact with 12 V cir- Connect T-adapter to female side of connector P02.
cuit) 4. Turn the starting switch to ON position (with connector disconnected).
Voltage Between P02 (female) (3) and ground 4.5 to 5.5 V
1. Turn the starting switch to OFF position.
Ground fault in wiring
harness 2. Disconnect connectors CP01, P02 to P03, P11, and P12.
3
(Contact with ground cir- 3. Connect T-adapter to female side of connector CP01.
cuit)
Resistance Between CP01 (female) (8) and ground Min. 1 MΩ
Defective machine con- If no failure is found by preceding checks, work equipment controller is defective.
4
troller (Since this is an internal defect, troubleshooting cannot be performed.)

PC45MR-5, PC55MR-5 40-141

FAILURE CODE [DBH5KP] 40 TROUBLESHOOTING

Circuit diagram related to machine controller 5V sensor power supply

40-142 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING FAILURE CODE [DBH5KP]

FAILURE CODE [DBH5KP]

Action level Failure code 5 V Sensor 1 Power Voltage Low Error (for proportional lever spec)
Failure
- DBH5KP (Machine controller system)
Detail of fail-
Voltage of 5 V sensor power supply output 1 circuit is 2.5 V and below or 6.0 V and above.
ure
• Stops output of power from 5 V sensor power supply output 1.
Action of
• Even if cause of failure is eliminated, machine does not become normal until the starting
controller
switch is turned to OFF position.
• Signal of pressure sensor is not input properly.
• The error code for the pressure sensor is displayed at the same time.
• Travel and work equipment speeds are slow.
Phenomenon
• Auto-decelerator function remains activated or fine control performance of work equipment
on machine
is poor.
• Potentiometer signal of service lever 1 (R.H. lever) is not input correctly.
• Potentiometer error code of service lever 1 (R.H. lever) is displayed at the same time.
Related After completion of repair, check if the failure code is cleared by the following procedure.
information Procedure: Turn the starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect connectors of the following sensors one by one and turn the
starting switch to ON position each time.
REMARK
• If this failure code goes out, disconnected sensor is defective.
Defective pressure sen- • Since connector is disconnected, other failure codes are displayed. Ig-
1 sor nore all of displayed failure codes other than this one.
(internal short circuit) 3. Each time troubleshooting is finished, return to step 1.
Travel pressure sensor P02
Swing parking brake lock pressure sensor P03
Connector
Service pressure sensor 1 (dummy) P11
Service pressure sensor 2 (dummy) P12
1. Turn the starting switch to OFF position.
2. Disconnect connector F26.
3. Turn the starting switch to ON position.
Defective service lever 1
2 (right iever) potentiome- REMARK
ter (internal short circuit)
• Since connector is disconnected, other failure codes are displayed. Ignore
all of displayed failure codes other than this one.
• If this failure code goes out, disconnected sensor is defective.
Measure voltage before controller stops output of power.
1. Turn the starting switch to OFF position.
Hot short circuit in wiring
harness 2. Disconnect connectors P02 to P03, P11, P12, and F26.
3 3.
(Contact with 12 V cir- Connect T-adapter to female side of connector P02.
cuit) 4. Turn the starting switch to ON position (with connector disconnected).
Voltage Between P02 (female) (3) and ground 4.5 to 5.5 V

PC45MR-5, PC55MR-5 40-143

FAILURE CODE [DBH5KP] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
Ground fault in wiring
harness 2. Disconnect connectors CP01, P02 to P03, P11, P12, and F26.
4
(Contact with ground cir- 3. Connect T-adapter to female side of connector CP01.
cuit)
Resistance Between CP01 (female) (8) and ground Min. 1 MΩ

Circuit diagram related to machine controller 5V sensor power supply (propor-

tional lever spec)

40-144 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING FAILURE CODE [DBH9KQ]

FAILURE CODE [DBH9KQ]

Action level Failure code Model Selection Signal Mismatch (Machine Controller)
Failure
L01 DBH9KQ (Machine controller system)
Detail of fail-
Model code signal for model which is not registered in controller is input.
ure
Controls machine by regarding it as default model (PC55MR standard specification machine).
Action of
Even if cause of failure disappears, machine does not become normal until the starting switch is
controller
turned to OFF position.
Phenomenon
No problem appears if machine is PC55MR standard specification machine.
on machine
• Part number of machine controller assembly can be checked with monitoring function.
(Code: 20294)
• Signal state (ON/OFF) of model selection signal can be checked with monitoring function.
(Code: 02201)
• PC55MR-5
Related Model selection signal 1: ON
information Model selection signal 2: OFF
• PC45MR-5
Model selection signal 1: OFF
Model selection signal 2: ON
• After completion of repair, check if the failure code is cleared by the following procedure.
Procedure: Turn the starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Defective model selec-
tion connector 2. Disconnect connector S30, and connect T-adapter to female side.
1 (Internal open or short Between S30 (female) (A) and (C) Max. 1 Ω
circuit)
Resistance Between S30 (female) (A) and (B) Min. 1 MΩ
(PC55MR-5)
Between S30 (female) (B) and (C) Min. 1 MΩ
1. Turn starting switch to OFF position.
Defective model selec-
tion connector 2. Disconnect connector S30, and connect T-adapter to female side.
2 (Internal open or short Between S30 (female) (B) and (C) Max. 1 Ω
circuit)
Resistance Between S30 (female) (A) and (B) Min. 1 MΩ
(PC45MR-5)
Between S30 (female) (A) and (C) Min. 1 MΩ
Open circuit in wiring har- 1. Turn starting switch to OFF position.
ness 2. Disconnect connector CP01 and connect T-adapter to female side.
3 (Wire breakage or defec-
tive contact of connector)
Resistance Between CP01 (female) (63) and ground Max. 1 Ω
(PC55MR-5)
Open circuit in wiring har- 1. Turn starting switch to OFF position.
ness 2. Disconnect connector CP01 and connect T-adapter to female side.
4 (Wire breakage or defec-
tive contact of connector)
Resistance Between CP01 (female) (57) and ground Max. 1 Ω
(PC45MR-5)

PC45MR-5, PC55MR-5 40-145

FAILURE CODE [DBH9KQ] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

Short circuit in wiring har- 1. Turn starting switch to OFF position.
ness 2. Disconnect connectors CP01 and S30, and insert T-adapters to S30.
5
(PC55MR-5)
(PC45MR-5) Resistance Between S30 (A) and (B) Min. 1 MΩ

Ground fault in wiring 1. Turn starting switch to OFF position.

harness 2. Disconnect connector CP01 and connect T-adapter to female side.
6 (Contact with ground cir-
cuit)
Resistance Between CP01 (female) (57) and ground Min. 1 MΩ
(PC55MR-5)
Ground fault in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connector CP01 and connect T-adapter to female side.
7 (Contact with ground cir-
cuit)
Resistance Between CP01 (female) (63) and ground Min. 1 MΩ
(PC45MR-5)
Machine controller with Display assembly part No. with monitoring function and check if it is same as part
8
wrong part number No. in the parts book.
Defective machine con- If no failure is found by preceding checks, work equipment controller is defective.
9
troller (Since this is an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to machine model setting system

40-146 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING FAILURE CODE [DBHLKA]

FAILURE CODE [DBHLKA]

Action level Failure code System Operating Lamp Open Circuit (Machine Controller)
Failure
- DBHLKA (Machine controller system)
Machine controller determines that system operating lamp circuit is open because voltage of output
Detail of fail-
circuit remains at approximately. 5 V or less for approximately 3 seconds after starting switch is
ure
turned to ON position, during which machine controller outputs no current to system operating lamp.
Action of
None in particular
controller

Phenomenon While system operating lamp is lit, battery disconnect switch must not be turned to OFF position. If
the battery disconnect switch is turned to OFF position, the memory data stored in the machine con-
on machine troller and the engine controller may be destroyed.
• This failure code is displayed only when the battery disconnect switch is set effectively.
• After completion of repair, check if the failure code is cleared by the following procedure.
Procedure: Turn the starting switch to ON position.
Related • Although machine controller is not able to light up system operating lamp, no trouble will
information result unless battery disconnect switch is turned to OFF position.
• When controller lights up system operating lamp, output circuit voltage is at low level.
• Since no controller drives system operating lamp for approximately 3 seconds after start-
ing switch is turned to ON position, open circuit can be detected.

No. Cause Procedure, measuring location, criteria and remarks

1 Defective fuse If fuse No.12 in fuse box FB1 is blown out, circuit probably has ground fault, etc.
1. Turn the starting switch to OFF position.
Open circuit in wiring har- 2. Remove fuse No.12 in fuse box FB1
ness (wire breakage or 3. Disconnect connector CP02 and connect T-adapter to female side.
2
defective contact of con-
nector) Between FB1-12 and M22 (female) (1) Max. 1 Ω
Resistance
Between CP02 (female) (99) and M22 (female) (2) Max. 1 Ω
Defective machine con- If no failure is found by preceding checks, work equipment controller is defective.
3
troller (Since this is an internal defect, troubleshooting cannot be performed.)

PC45MR-5, PC55MR-5 40-147

FAILURE CODE [DBHLKA] 40 TROUBLESHOOTING

Circuit diagram related to system operating lamp

40-148 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING FAILURE CODE [DBHLKB]

FAILURE CODE [DBHLKB]

Action level Failure code System Operating Lamp Short Circuit (Machine Controller)
Failure
- DBHLKB (Machine controller system)
Machine controller determines that system operating lamp circuit shorts because voltage of output
Detail of fail-
circuit does not become Low level while machine controller outputs current to system operating
ure
lamp.
Action of
None in particular
controller

Phenomenon While system operating lamp is lit, battery disconnect switch must not be turned to OFF position. If
the battery disconnect switch is turned to OFF position, the memory data stored in the machine con-
on machine troller and the engine controller may be destroyed.
• This failure code is displayed only when the battery disconnect switch is set effectively.
• After completion of repair, check if the failure code is cleared by the following procedure.
Related Procedure: Turn the starting switch to ON position.
information • Although machine controller is not able to light up system operating lamp, no trouble will
result unless battery disconnect switch is turned to OFF position.
• When controller lights up system operating lamp, output circuit voltage is at low level.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Remove fuse No.12 in fuse box FB1
Short circuit in wiring har-
1 3. Disconnect connectors F15, CP02, CK01, and M22, and connect T-adapt-
ness
er to female side of M22.
Resistance Between M22 (female) (1) and (2) Min. 1 MΩ
1. Turn the starting switch to OFF position.
Hot short circuit in wiring 2. Disconnect connector M22, and connect T-adapter to female side.
2
harness 3. Turn the starting switch to ON position.
Voltage Between M22 (female) (2) and ground Max. 1 V
Defective machine con- If no failure is found by preceding checks, work equipment controller is defective.
3
troller (Since this is an internal defect, troubleshooting cannot be performed.)

PC45MR-5, PC55MR-5 40-149

FAILURE CODE [DBHLKB] 40 TROUBLESHOOTING

Circuit diagram related to system operating lamp

40-150 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING FAILURE CODE [DBHQKR]

FAILURE CODE [DBHQKR]

Action level Failure code Controller Area NW 2 Defect Communicat (Machine Controller)
Failure
L03 DBHQKR (Machine monitor system)
Detail of fail- Machine monitor does not recognize machine controller through CAN communication 2 line (KOM-
ure NET/c).
Action of
Retains information at time of occurrence of failure.
controller

Phenomenon Information to be obtained from machine controller is not displayed and special functions that need
information do not work. Or update of received data is stopped (such as failure codes and monitor-
on machine ing codes sent from the machine controller and the engine controller).
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.
• Start of CAN communication is recognized by each controller when ACC signal of starting
switch is received.
• 2 different failure codes, [DBHQKR], and [D8AQKR], are used for defective CAN commu-
nication by CAN2 when it is detected by machine monitor. When all of these 2 failure co-
Related des are displayed, ground fault, short circuit or hot short in wiring harness (CAN communi-
information cation circuit) can be suspected. Since air conditioner is also operated through CAN com-
munication, you must, in such case, check on air conditioner screen whether air condition-
er is operable (ON/OFF and air flow of air conditioner).
• Since each controller and machine monitor are connected directly to battery, they are sup-
plied with power even after starting switch is turned to OFF position.
• Since signal of active CAN communication line is pulse voltage, it cannot be measured by
using multimeter.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect fusible link M09 and connect T-adapter to male side.
1 Defective fusible link Resistance Between M09 (male) (1) and (2) Max. 1 Ω

REMARK
If fusible link is blown out, circuit probably has ground fault.
1. Turn starting switch to OFF position.
2 Defective fuse 2. Remove fuse No. 13 in fuse box FB1.
If fuse is blown, circuit probably has ground fault.

REMARK
Check ground terminal T01 for looseness and rust.
1. Turn starting switch to OFF position.
Improper power supply to 2.
3 Disconnect connector CP01 and connect T-adapter to female side.
machine controller
3. Turn starting switch to ON position.
Between CP01 (female) (1) and (2) 10 to 15 V
Voltage
Between CP01 (female) (4) and (5) 10 to 15 V

PC45MR-5, PC55MR-5 40-151

FAILURE CODE [DBHQKR] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

REMARK
If failure code is still displayed after above checks on cause 3, this check is not
required.
1. Turn the starting switch to OFF position.
2. Disconnect the battery ground, or turn the battery disconnect switch to
OFF position.
Open circuit in wiring har-
3. Remove fuse No. 13 in fuse box FB1.
ness
4 4. Disconnect fusible link and connector CP01, and connect T-adapters to
(Wire breakage or defec-
tive contact of connector) each female side connector.
Between battery (+) and M09 (female) (2) Max. 1 Ω
Between M09 (female) (1) and F01(female) (2) Max. 1 Ω
Resistance Between F01(female) (2) and FB1-11B Max. 1 Ω
Between FB1-13 and CP01 (female) (1) Max. 1 Ω
Between FB1-13 and CP01 (female) (4) Max. 1 Ω
1. Turn the starting switch to OFF position.
Defective CAN terminat- 2. Disconnect connectors CP01, and F15, and connect T-adapter to male
ing resistor side.
5
(internal open or short
Between CP01 (male) (7) and (14) 120±12 Ω
circuit) Resistance
Between F15 (male) (11) and (12) 120±12 Ω
CAN communication line
REMARK
CAN terminating resistor of 120 Ω are located in machine monitor and machine
controller. That is, CAN terminating resistors of 120 Ω are connected in parallel.
When circuit resistance is measured at connector of controller other than machine
monitor and machine controller, if combined resistance is 60 Ω, wiring harness
does not have open circuit.
1. Turn the starting switch to OFF position.
2. Disconnect the battery ground, or turn the battery disconnect switch to
OFF position.
Open or short circuit in 3. Disconnect related connectors, and connect T-adapter to connector to be
6 measured.
wiring harness
REMARK
If short circuit is found (resistance between 2 terminals is 1 Ω or less), disconnect
all CAN communication connectors of every controller and check whether short cir-
cuit occurs between wiring harnesses or inside controller.
Approx.
Between F15 (female) (11) and (12)
120 Ω
Approx.
Resistance Between CK01 (female) (10) and (11)
60 Ω
Approx.
Between CP01 (female) (7) and (26)
120 Ω

40-152 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING FAILURE CODE [DBHQKR]

No. Cause Procedure, measuring location, criteria and remarks

ACC signal of starting switch (start of CAN communication is not recognized)
1. Turn the starting switch to OFF position.
2. Disconnect the battery ground, or turn the battery disconnect switch to
OFF position.
3. Disconnect connectors to be measured and insert T-adapters.
4. Connect the battery ground, or turn the battery disconnect switch to ON
position.
5. Turn the starting switch to ON position.
Between F15 (3) and (2) 10 to 15 V
Voltage Between CK02 (3) and (1) 10 to 15 V
Between CP01 (17) and (2) 10 to 15 V
Open circuit in wiring har-
ness REMARK
7
(Wire breakage or defec- If failure code is still displayed after above checks on cause 6, this check is not
tive contact of connector) required.
1. Turn the starting switch to OFF position.
2. Disconnect the battery ground, or turn the battery disconnect switch to
OFF position.
3. Disconnect related connectors, and connect T-adapter to each female side
connector to be measured.
Between F15 (female) (11) and CP01 (female) (7) Max. 1 Ω
Between F15 (female) (12) and CP01 (female) (26) Max. 1 Ω
Resistance Between F15 (female) (11) and CK01 (female) (10) Max. 1 Ω
Between F15 (female) (12) and CK01 (female) (11) Max. 1 Ω
Between CP01 (female) (14) and CP01 (female) (33) Max. 1 Ω
If no failure (no open circuit) is found by check on cause 6, measure resistance at
any one place in each case.
1. Turn the starting switch to OFF position.
2. Disconnect the battery ground, or turn the battery disconnect switch to
Ground fault in wiring OFF position.
harness
8 3. Disconnect related connectors, and connect T-adapter to each female side
(Contact with ground cir- connector to be measured.
cuit)
Between ground and any point in CP01 (female) (7), or
Min. 1 MΩ
F15 (female) (11)
Resistance
Between ground and any point in CP01 (female) (26),
Min. 1 MΩ
or F15 (female) (12)

PC45MR-5, PC55MR-5 40-153

FAILURE CODE [DBHQKR] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

If no failure (no open circuit) is found by check on cause 6, measure resistance at
any one place in each case.
1. Turn the starting switch to OFF position.
2. Disconnect the battery ground, or turn the battery disconnect switch to
Open circuit or hot short OFF position.
circuit in wiring harness 3. Insert T-adapter into connector to measure.
9
(Contact with 12 V cir- 4. Connect the battery ground, or turn the battery disconnect switch to ON
cuit) position.
5. Turn starting switch to ON position.
Between ground and any of F15 (11), and CK01 (10) 1 to 4 V
Voltage
Between ground and any of F15 (12), and CK01 (11) 1 to 4 V
If all four failure codes [DBHQKR], and [D8AQKR] are displayed:
To identify defective controller, repeat following steps 1. to 3. to disconnect control-
lers one by one from CAN communication line.
1. Turn the starting switch to OFF position.
2. Disconnect the battery ground, or turn the battery disconnect switch to
OFF position.
Defective machine con- 3. Disconnect CAN communication connector of machine controller (connec-
10 troller, or KOMTRAX ter- tor CP01), and KOMTRAX terminal (connector CK01) one by one in turn.
minal
4. Connect the battery ground, or turn the battery disconnect switch to ON
position.
5. Turn starting switch to ON position.
6. Return to step 1 to check next controller.
Has the number of displayed failure co- If YES, the disconnected controller is de-
des decreased from 2? fective.
Defective machine con- If no failure is found by preceding checks, work equipment controller is defective.
11
troller (Since this is an internal defect, troubleshooting cannot be performed.)
Defective machine moni- If no failure is found by above checks, machine monitor is defective. (Since this is
12
tor an internal defect, troubleshooting cannot be performed.)

40-154 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING FAILURE CODE [DBHQKR]

Circuit diagram related to CAN2 communication

PC45MR-5, PC55MR-5 40-155

FAILURE CODE [DDNRKA] 40 TROUBLESHOOTING

FAILURE CODE [DDNRKA]

Action level Failure code Work Equipment Lever Lock Switch Open Circuit
Failure
L03 DDNRKA (Machine controller system)

• No current flows on the PPC lock lever relay side when the work equipment lock lever is in
Detail of fail- RELEASE position, so the open circuit is detected.
ure • No current flows on the controller side when the work equipment lock lever is in LOCK po-
sition, so the open circuit is detected.
Action of • None in particular (Lock lever automatic lock control may operate wrongly.)
controller • If cause of failure disappears, machine becomes normal by itself.
Phenomenon • Starting motor does not start.
on machine • All work equipment, swing and travel does not work.
• State of lock lever can be checked with monitoring function. (Code: 02203)
Related • After completion of repair, check if the failure code is cleared by the following procedure.
information Procedure: Turn the starting switch to ON position, and lock and unlock work equipment
lock lever.

No. Cause Procedure, measuring location, criteria and remarks

1 Defective fuse If fuse No.3 in fuse box FB1 is blown out, circuit probably has ground fault, etc.
Defective work equip- Perform troubleshooting for failure code [DDNRKY].
2
ment lever lock switch
1. Turn the starting switch to OFF position.
2. Disconnect connectors CP01 and F09, and connect T-adapter to female
side of CP01 and male side of F09.
Open circuit in wiring har-
3
ness Between F09 (male) (A) and FB1 (3) Max. 1 Ω
Resistance Between CP01 (female) (41) and F09 (male) (C) Max. 1 Ω
Between CP01 (female) (22) and F09 (male) (B) Max. 1 Ω
Defective machine con- If no failure is found by preceding checks, work equipment controller is defective.
4
troller (Since this is an internal defect, troubleshooting cannot be performed.)

40-156 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING FAILURE CODE [DDNRKA]

Circuit diagram related to PPC lock switch

PC45MR-5, PC55MR-5 40-157

FAILURE CODE [DDNRKY] 40 TROUBLESHOOTING

FAILURE CODE [DDNRKY]

Action level Failure code Work Equipment Lever Lock Switch Hot Short Circuit
Failure
L03 DDNRKY (Machine controller system)
• When the work equipment lock lever is in RELEASE position, PPC lock signal voltage of
Detail of fail- controller side circuit is 5.2 V and above.
ure • When the work equipment lock lever is in LOCK position, signal voltage of PPC lock lever
relay side circuit is 5.2 V and above.
Action of • Stops driving PPC lock relay.
controller • If cause of failure disappears, machine becomes normal by itself.
Phenomenon
None of work equipment, swing or travel works.
on machine
• State of lock lever can be checked with monitoring function. (Code: 02203)
Related • After completion of repair, check if the failure code is cleared by the following procedure.
information Procedure: Turn the starting switch to ON position, and operate the work equipment lock
lever to lock or release.

No. Cause Procedure, measuring location, criteria and remarks

Defective work equip- Perform troubleshooting for failure code [DDNRKY].
1
ment lever lock switch
1. Turn the starting switch to OFF position.
2. Disconnect connector F09, and connect T-adapter to male side.
Hot short circuit in wiring
2
harness Between F09 (male) (B) and ground Max. 1 V
Voltage
Between F09 (male) (C) and ground Max. 1 V
Defective machine con- If no failure is found by preceding checks, work equipment controller is defective.
3
troller (Since this is an internal defect, troubleshooting cannot be performed.)

40-158 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING FAILURE CODE [DDNRKY]

Circuit diagram related to PPC lock switch

PC45MR-5, PC55MR-5 40-159

FAILURE CODE [DDNS00] 40 TROUBLESHOOTING

FAILURE CODE [DDNS00]

Action level Failure code Lock Lever Auto Lock Release Switch Operation
Failure
- DDNS00 (Machine controller system)

Details of Lock lever automatic lock release switch operation is detected when lock lever is locked automati-
failure cally.

Action of • None in particular

controller • Lock lever automatic lock does not operate.
Phenomenon • Lock lever automatic lock function does not operate.
on machine • Automatic lock release switch monitor is displayed in red on machine monitor.
• Connectors CP01 and S25 do not provide T-adapter for measuring voltage, and use con-
Related nector D01 for troubleshooting.
information • After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position and set PPC lock lever to FREE position.

No. Cause Procedure, measuring location, criteria and remarks

Lock lever automatic lock If lock lever automatic lock function operates normally, turn lock lever automatic
1
cancel switch ON lock cancel switch OFF.
1. Turn the starting switch to OFF position.
Hot short circuit in wiring 2. Disconnect connector D01, and connect T-adapter to female side.
2
harness 3. Turn the starting switch to ON position.
Voltage Between D01 (female) (5) and ground Max. 1 V
Defective machine con- If no failure is found by preceding checks, work equipment controller is defective.
3
troller (Since this is an internal defect, troubleshooting cannot be performed.)

40-160 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING FAILURE CODE [DDNS00]

Circuit diagram related to PPC lock switch

PC45MR-5, PC55MR-5 40-161

FAILURE CODE [DDWLKA] 40 TROUBLESHOOTING

FAILURE CODE [DDWLKA]

Action level Failure code Breaker Switch Open Circuit or Ground Fault
Failure
- DDWLKA (Machine controller system)
Detail of fail- Since there is open circuit or ground fault in breaker switch signal system, both main signal and sub
ure signal of breaker switch become open.
Action of • Stops driving attachment flow rate adjustment EPC2 solenoid.
controller • Stops driving attachment flow rate adjustment EPC5 solenoid.
Phenomenon
Breaker does not function.
on machine
• This failure code is displayed only when attachment 1 (with Attachment) or attachment 2
(with Attachment) is set.
Related • By releasing the breaker switch, main signal of breaker switch becomes OPEN, and sub
information signal becomes CLOSE.
• By pushing the breaker switch, main signal of breaker switch becomes CLOSE, and sub
signal becomes OPEN.

No. Cause Procedure, measuring location, criteria and remarks

1 Defective fuse If fuse FB1 (No.5) is blown out, circuit probably has ground fault, etc.
1. Turn the starting switch to OFF position.
2. Disconnect connector F26, and connect T-adapter to male side.
3. Breaker switch OFF
REMARK
Switch OFF: Release
Switch ON: Push
Defective breaker switch
2 (internal open circuit or Between F26 (male) (6)
Switch OFF Max. 1 Ω
short circuit) and (8)
Between F26 (male) (6)
Switch ON Min. 1 MΩ
and (8)
Resistance
Between F26 (male) (6)
Switch OFF Min. 1 MΩ
and (1)
Between F26 (male) (6)
Switch ON Max. 1 Ω
and (1)
1. Turn the starting switch to OFF position.
2. Disconnect connectors CP01 and F26, and connect T-adapters to each fe-
Open circuit in wiring har-
ness male side.
3
(Wire breakage or defec- Between CP01 (female) (36) and F26 (female) (1) Max. 1 Ω
tive contact of connector) Resistance Between CP01 (female) (55) and F26 (female) (8) Max. 1 Ω
Between FB1 (5) and F26 (female) (6) Max. 1 Ω
Defective machine con- If no failure is found by preceding checks, work equipment controller is defective.
4
troller (Since this is an internal defect, troubleshooting cannot be performed.)

40-162 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING FAILURE CODE [DDWLKA]

Circuit diagram related to breaker switch

PC45MR-5, PC55MR-5 40-163

FAILURE CODE [DDWLKB] 40 TROUBLESHOOTING

FAILURE CODE [DDWLKB]

Action level Failure code Breaker Switch Hot Short Circuit
Failure
- DDWLKB (Machine controller system)
Detail of fail- Since there is hot short circuit in breaker switch signal system, both main signal and sub signal of
ure breaker switch become CLOSE.
Action of • Stops driving attachment flow rate adjustment EPC2 solenoid.
controller • Stops driving attachment flow rate adjustment EPC5 solenoid.
Phenomenon
Breaker does not function.
on machine
• This failure code is displayed only when attachment 1 (with Attachment) or attachment 2
(with Attachment) is set.
Related • By releasing the breaker switch, main signal of breaker switch becomes OPEN, and sub
information signal becomes CLOSE.
• By pushing the breaker switch, main signal of breaker switch becomes CLOSE, and sub
signal of breaker switch becomes OPEN.

No. Cause Procedure, measuring location, criteria and remarks

1 Defective fuse If fuse FB1 (No.5) is blown out, circuit probably has ground fault, etc.
1. Turn the starting switch to OFF position.
2. Disconnect connector F26, and connect T-adapter to male side.
3. Breaker switch OFF
REMARK
Switch OFF: Release
Switch ON: Push
Defective breaker switch
2 (internal open circuit or Between F26 (male) (6)
Switch OFF Max. 1 Ω
short circuit) and (8)
Between F26 (male) (6)
Switch ON Min. 1 MΩ
and (8)
Resistance
Between F26 (male) (6)
Switch OFF Min. 1 MΩ
and (1)
Between F26 (male) (6)
Switch ON Max. 1 Ω
and (1)
1. Turn the starting switch to OFF position.
2. Disconnect connectors CP01 and F26, and connect T-adapter to either fe-
Hot short circuit in wiring male side.
3
harness
Between F26 (female) (1) and ground Max. 1 V
Voltage
Between F26 (female) (6) and ground Max. 1 V
Defective machine con- If no failure is found by preceding checks, work equipment controller is defective.
4
troller (Since this is an internal defect, troubleshooting cannot be performed.)

40-164 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING FAILURE CODE [DDWLKB]

Circuit diagram related to breaker switch

PC45MR-5, PC55MR-5 40-165

FAILURE CODE [DFB1KZ] 40 TROUBLESHOOTING

FAILURE CODE [DFB1KZ]

Action level Failure code Service Lever Potentio 1 Open or Short Circuit
Failure
L01 DFB1KZ (Machine controller system)
Detail of fail- When attachment proportional switch of service lever 1 (right lever) was used, abnormality was de-
ure tected in circuit.
Action of • Stops driving attachment flow rate adjustment EPC2 solenoid.
controller • Stops driving attachment flow rate adjustment EPC5 solenoid.
Phenomenon
Attachment does not operate.
on machine
• This failure code is displayed only when attachment 1 (with Attachment) or attachment 2
(with Attachment) is set.

Related • Service lever 1 (right lever) potentiometer 1 signal voltage can be checked with the moni-
toring function (code: 42008).
information
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn the starting switch to ON position and set machine in attachment mode
(ATT).

No. Cause Procedure, measuring location, criteria and remarks

Defective 5 V sensor 1 If failure code [DBH5KP] is also displayed, perform troubleshooting these first.
1
power supply system
1. Turn the starting switch to OFF position.
2. Disconnect connector F26, and connect T-adapter to female side.
Defective service lever 1 3. Turn the starting switch to ON position.
2 (right iever) potentiome-
ter (internal defect) RAISE 4.3±0.2 V
Between F26 (female) (5)
Voltage NEUTRAL 2.5 V
and (4)
LOWER 0.7±0.2 V
1. Turn starting switch to OFF position.
2. Disconnect connector CP01 and F26, and connect T-adapters to each fe-
Open circuit in wiring har- male side.
3
ness
Between CP01 (female) (68) and F26 (5) Max. 1 Ω
Resistance
Between CP01 (female) (8) and F26 (2) Max. 1 Ω
Ground fault in wiring 1. Turn starting switch to OFF position.
harness 2.
4 Disconnect connector CP01, and connect T-adapter to female side.
(Contact with ground cir-
cuit) Resistance Between CP01 (female) (68) and ground Min. 1 MΩ
1. Turn the starting switch to OFF position.
2. Disconnect connector CP01, and connect T-adapter to female side.
4.0 to
Between CP01 (female) (13) and (8)
6.0 kΩ
Defective machine con-
5 0.25 to
troller Between CP01 (female) (68) and (13)
Resistance 5.0 kΩ
0.25 to
Between CP01 (female) (68) and (8)
5.0 kΩ
Between CP01 (female) (68) and ground Min. 1 MΩ

40-166 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING FAILURE CODE [DFB1KZ]

Circuit diagram related to service lever potentio 1

PC45MR-5, PC55MR-5 40-167

FAILURE CODE [DFB3L8] 40 TROUBLESHOOTING

FAILURE CODE [DFB3L8]

Action level Failure code Service Lever 1 Potentio Signal Incompatibility
Failure
- DFB3L8 (Machine controller system)
Detail of fail- When attachment proportional switch of service lever 1 (right lever) was used, abnormality was de-
ure tected in circuit.
Action of • Stops driving attachment flow rate adjustment EPC2 solenoid.
controller • Stops driving attachment flow rate adjustment EPC5 solenoid.
Phenomenon
Attachment does not operate.
on machine
• This failure code is displayed only when attachment 1 (with Attachment) or attachment 2
(with Attachment) is set.

No. Cause Procedure, measuring location, criteria and remarks

Defective 5 V sensor 1 If failure code [DBH5KP] is also displayed, perform troubleshooting these first.
1
power supply system
1. Turn the starting switch to OFF position.
2. Disconnect connector F26, and connect T-adapter to female side.
3. Turn the starting switch to ON position.
RAISE 4.3±0.2 V
Defective service lever 1 Between F26 (female) (5)
2 (right iever) potentiome- NEUTRAL 2.5 V
and (4)
ter (internal defect) LOWER 0.7±0.2 V
Voltage
RAISE 0.7±0.2 V
Between F26 (female) (3)
NEUTRAL 2.5 V
and (4)
LOWER 4.3±0.2 V
1. Turn starting switch to OFF position.
2. Disconnect connector CP01 and F26, and connect T-adapters to each fe-
male side.
Open circuit in wiring har-
3
ness Between CP01 (female) (68) and F26 (5) Max. 1 Ω
Resistance Between CP01 (female) (30) and F26 (3) Max. 1 Ω
Between CP01 (female) (8) and F26 (2) Max. 1 Ω
1. Turn starting switch to OFF position.
Ground fault in wiring
harness 2. Disconnect connector CP01, and connect T-adapter to female side.
4
(Contact with ground cir- Between CP01 (female) (68) and ground Min. 1 MΩ
cuit) Resistance
Between CP01 (female) (30) and ground Min. 1 MΩ

40-168 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING FAILURE CODE [DFB3L8]

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect connector CP01, and connect T-adapter to female side.
4.0 to
Between CP01 (female) (13) and (8)
6.0 kΩ
0.25 to
Between CP01 (female) (68) and (13)
5.0 kΩ
Defective machine con-
5 0.25 to
troller Between CP01 (female) (68) and (8)
Resistance 5.0 kΩ
0.25 to
Between CP01 (female) (30) and (13)
5.0 kΩ
0.25 to
Between CP01 (female) (30) and (8)
5.0 kΩ
Between CP01 (female) (68) and ground Min. 1 MΩ

Circuit diagram related to service lever potentio 1

PC45MR-5, PC55MR-5 40-169

FAILURE CODE [DFB5KZ] 40 TROUBLESHOOTING

FAILURE CODE [DFB5KZ]

Action level Failure code Service Lever sub-Potentio 1 Open or Short Circuit
Failure
- DFB5KZ (Machine controller system)
Detail of fail- When attachment proportional switch of service lever 1 (right lever) was used, abnormality was de-
ure tected in circuit.
Action of • Stops driving attachment flow rate adjustment EPC2 solenoid.
controller • Stops driving attachment flow rate adjustment EPC5 solenoid.
Phenomenon
Attachment does not operate.
on machine
• This failure code is displayed by only machine equipped with attachment proportional
switch.

Related • Service lever 1 (right lever) potentiometer 2 signal voltage can be checked with the moni-
toring function (code: 42009).
information
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn the starting switch to ON position and set machine in attachment mode
(ATT).

No. Cause Procedure, measuring location, criteria and remarks

Defective 5 V sensor 1 If failure code [DBH5KP] is also displayed, perform troubleshooting these first.
1
power supply system
1. Turn the starting switch to OFF position.
2. Disconnect connector F26, and connect T-adapter to female side.
Defective service lever 1 3. Turn the starting switch to ON position.
2 (right iever) potentiome-
ter (internal defect) RAISE 0.7±0.2 V
Between F26 (female) (3)
Voltage NEUTRAL 2.5 V
and (4)
LOWER 4.3±0.2 V
1. Turn starting switch to OFF position.
2. Disconnect connector CP01 and F26, and connect T-adapters to each fe-
Open circuit in wiring har- male side.
3
ness
Between CP01 (female) (30) and F26 (3) Max. 1 Ω
Resistance
Between CP01 (female) (8) and F26 (2) Max. 1 Ω
Ground fault in wiring 1. Turn starting switch to OFF position.
harness 2.
4 Disconnect connector CP01, and connect T-adapter to female side.
(Contact with ground cir-
cuit) Resistance Between CP01 (female) (30) and ground Min. 1 MΩ
1. Turn the starting switch to OFF position.
2. Disconnect connector CP01, and connect T-adapter to female side.
4.0 to
Between CP01 (female) (13) and (8)
6.0 kΩ
Defective machine con-
5 0.25 to
troller Between CP01 (female) (30) and (13)
Resistance 5.0 kΩ
0.25 to
Between CP01 (female) (30) and (8)
5.0 kΩ
Between CP01 (female) (68) and ground Min. 1 MΩ

40-170 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING FAILURE CODE [DFB5KZ]

Circuit diagram related to service lever potentio 1

PC45MR-5, PC55MR-5 40-171

FAILURE CODE [DHS1MA] 40 TROUBLESHOOTING

FAILURE CODE [DHS1MA]

Action level Failure code Swing PPC Pressure Sensor Abnormality
Failure
L01 DHS1MA (Machine controller system)
Detail of fail- Signal voltage of swing parking cancel PPC pressure sensor circuit is 0.3 V or less or 4.5 V or
ure above.
• Controls machine by regarding swing parking brake cancel PPC pressure sensor as
Action of
0 MPa 0 kg/cm2.
controller
• If cause of failure is eliminated, machine becomes normal by itself.
Phenomenon • Auto-deceleration function cannot be reset.
on machine • Poor operability of swing

REMARK
If 5 V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor
will break. Accordingly, take extreme care when checking.

Related • As T-adapter for machine controller connector is “socket-type box”, operating voltage can-
not be measured at machine controller connector.
information
• Swing parking brake cancel PPC pressure can be checked with monitoring function.
(Code: 09000)
• After completion of repair, check if the failure code is cleared by the following procedure.
Procedure: Turn the starting switch to ON position or start the engine.

No. Cause Procedure, measuring location, criteria and remarks

If failure code [DBH5KP] is also displayed, perform troubleshooting these first.
1. Turn starting switch to OFF position.
2. Disconnect connector P03, and connect T-adapter to female side.
Defective 5 V sensor
1 3. Turn starting switch to ON position.
power supply 1 system
If power supply voltage is abnormal, proceed to check on cause 3.
Between P03 (female) (3)
Voltage Power supply 4.5 to 5.5 V
and (1)
If no failure is found by check on cause 1, checks of resistance 1 and 3 on cause 3
are not required.
1. Turn starting switch to OFF position.
Open circuit in wiring har-
2. Disconnect connector CP01 and P03, and connect T-adapters to each fe-
ness
2 male side.
(Wire breakage or defec-
tive contact of connector) Between CP01 (female) (8) and P03 (female) (3) Max. 1 Ω
Resistance Between CP01 (female) (47) and P03 (female) (1) Max. 1 Ω
Between CP01 (female) (48) and P03 (female) (2) Max. 1 Ω
1. Turn starting switch to OFF position.
Ground fault in wiring
2. Disconnect connectors CP01 and P03, and connect T-adapter to either fe-
harness
3 male side.
(Contact with ground cir-
cuit) Between ground and CP01 (female) (48) or P03 (fe-
Resistance Min. 1 MΩ
male) (2)
1. Turn starting switch to OFF position.
Hot short circuit in wiring
harness 2. Disconnect connector P03, and connect T-adapter to female side.
4
(Contact with 5V / 24V 3. Turn starting switch to ON position.
circuit)
Voltage Between P03 (female) (2) and ground Max. 1 V

40-172 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING FAILURE CODE [DHS1MA]

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Insert the T-adapter into connector P03.
3. Turn the starting switch to ON position.
Voltage Between P03 (2) and (1) 0.5 to 4.5 V

REMARK
If power supply voltage is normal and sensor output voltage is abnormal, it is diffi-
cult to determine the failure between ground fault and hot short circuit in wiring har-
Defective PPC pressure
ness. Check as follows.
5 sensor for swing parking
brake release 1. Turn the starting switch to OFF position.
2. Replace connector P03 with connector of another PPC pressure sensor.
3. Turn the starting switch to ON position and display the Electrical Sys Ab-
normality Record screen of machine monitor.
4. If E mark is not displayed again in this failure code column, swing parking
brake release PPC pressure sensor is defective.
REMARK
After the troubleshooting, always restore the connector.
Defective machine con- If no failure is found by preceding checks, work equipment controller is defective.
6
troller (Since this is an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to swing PPC pressure sensor

PC45MR-5, PC55MR-5 40-173

FAILURE CODE [DHS5MA] 40 TROUBLESHOOTING

FAILURE CODE [DHS5MA]

Action level Failure code Travel PPC Pressure Sensor Error
Failure
L01 DHS5MA (Machine controller system)
Detail of fail-
Signal voltage of travel PPC pressure sensor circuit is 0.3 V or less or 4.5 V or above.
ure
Action of • Controls machine by regarding travel PPC pressure sensor as 0 MPa {0 kg/cm2} .
controller • If cause of failure disappears, machine becomes normal by itself.
Phenomenon • Auto-deceleration function cannot be reset.
on machine • Poor operability of travel.
• As T-adapter for machine controller connector is “socket-type box”, operating voltage can-
not be measured at machine controller connector.
• Travel PPC pressure can be checked with monitoring. (Code: 07101)
Related
information
• After completion of repair, check if the failure code is cleared by the following procedure.
Procedure: Turn the starting switch to ON position or start the engine.
k If 5 V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pres-
sure sensor will break. Accordingly, take extreme care when checking.

No. Cause Procedure, measuring location, criteria and remarks

If failure code [DBH5KP] is also displayed, perform troubleshooting these first.
1. Turn starting switch to OFF position.
2. Disconnect connector P02, and connect T-adapter to female side.
Defective 5 V sensor
1 3. Turn starting switch to ON position.
power supply 1 system
If power supply voltage is abnormal, proceed to check on cause 3.
Between P02 (female) (3)
Voltage Power supply 4.5 to 5.5 V
and (1)
1. Turn the starting switch to OFF position.
2. Insert the T-adapter into connector P02.
3. Turn the starting switch to ON position.
Voltage Between P02 (2) and (1) 0.5 to 4.5 V

REMARK
If power supply voltage is normal and sensor output voltage is not normal, it is diffi-
cult to judge whether cause of failure is ground fault or hot short circuit in wiring
Defective travel PPC
harness. Check as below.
2 pressure sensor (internal
defect) 1. Turn the starting switch to OFF position.
2. Exchange connector P02 with connector of another PPC pressure sensor.
3. Turn the starting switch to ON position, and display "Electrical Sys Abnor-
mality Record" screen on machine monitor.
4. If E mark is not displayed again in this failure code column, travel PPC
pressure sensor is defective.
NOTICE
After the troubleshooting, always restore the connector.

40-174 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING FAILURE CODE [DHS5MA]

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect connectors CP01 and P02, and connect T-adapters to each fe-
male side.

Open circuit in wiring har- If power supply voltage in check on cause 1 is normal,
ness (wire breakage or this check is not required. Max. 1 Ω
3
defective contact of con- Between CP01 (female) (47) and P02 (female) (1)
nector)
Resistance Between CP01 (female) (29) and P02 (female) (2) Max. 1 Ω
If power supply voltage in check on cause 1 is normal,
this check is not required. Max. 1 Ω
Between CP01 (female) (8) and P02 (female) (3)
1. Turn the starting switch to OFF position.
Ground fault in wiring 2. Disconnect connectors CP01 and P02, and connect T-adapter to either fe-
4 harness (contact with male side.
ground circuit)
Between ground and CP01 (female) (29) or P02 (fe-
Resistance Min. 1 MΩ
male) (2)
1. Turn the starting switch to OFF position.
2. Disconnect connector P02.
Hot short circuit in wiring
5 harness (contact with 3. Connect T-adapter to female side of connector P02.
5V / 24V circuit) 4. Turn the starting switch to ON position.
Voltage Between P02 (female) (2) and ground Max. 1 V
Defective machine con- If no failure is found by preceding checks, work equipment controller is defective.
6
troller (Since this is an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to travel PPC pressure sensor

PC45MR-5, PC55MR-5 40-175

FAILURE CODE [DKULKA] 40 TROUBLESHOOTING

FAILURE CODE [DKULKA]

Action level Failure code PPC Lock Relay Open Circuit
Failure
L03 DKULKA (Machine controller system)
Detail of fail- Open circuit is detected in the circuit when output to PPC lock relay (coil side) is stopped (during
ure lock lever automatic lock control operation).
Action of • None in particular (Since no current flows, relay is not operated.)
controller • If cause of failure disappears, machine becomes normal by itself.
Phenomenon
All work equipment, swing, and travel are not operated even when lock lever is in FREE position.
on machine
After completion of repair, check if the failure code is cleared by the following procedure.
Related
Procedure: Turn the starting switch to ON position, and release the lock lever while performing
information
boom RAISE.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect connector R02, and connect T-adapter to male side.
Resistance Between R02 (male) (1) and (2) 80 to 200 Ω
1 Defective PPC lock relay 1. Turn the starting switch to OFF position.
2. Replace relay R02 with another one.
3. Turn the starting switch to ON position.
If this failure code is cleared, the original PPC lock relay is defective.
1. Turn the starting switch to OFF position.
2. Disconnect connector CP02 and relay R02, and connect T-adapter to each
Open circuit in wiring har- female side.
2
ness
Between CP02 (female) (109) and R02 (female) (1) Max. 1 Ω
Resistance
Between R02 (female) (2) and ground Max. 1 Ω
Defective machine con- If no failure is found by preceding checks, work equipment controller is defective.
3
troller (Since this is an internal defect, troubleshooting cannot be performed.)

40-176 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING FAILURE CODE [DKULKA]

Circuit diagram related to PPC lock switch

PC45MR-5, PC55MR-5 40-177

FAILURE CODE [DKULKB] 40 TROUBLESHOOTING

FAILURE CODE [DKULKB]

Action level Failure code PPC Lock Relay Short Circuit
Failure
L03 DKULKB (Machine controller system)
Detail of fail-
Short circuit is detected when output to PPC lock relay (coil side) is ON.
ure
• Stops output to PPC lock relay.
Action of
• Even if cause of failure disappears, machine does not become normal until starting switch
controller
is turned to OFF position.
Phenomenon • All work equipment, swing, and travel are not operated even when lock lever is in FREE
on machine position.
Related After completion of repair, check if the failure code is cleared by the following procedure.
information Procedure: Turn starting switch to ON position and set PPC lock lever to FREE position.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect connector R02, and connect T-adapter to male side.
Resistance Between R02 (male) (1) and (2) 80 to 200 Ω
1 Defective PPC lock relay 1. Turn the starting switch to OFF position.
2. Replace relay R02 with another one.
3. Turn the starting switch to ON position.
If this failure code is cleared, the original PPC lock relay is defective.
1. Turn the starting switch to OFF position.
2. Disconnect connector CP02 and relay R02, and connect T-adapter to ei-
Ground fault in wiring
2 ther female side.
harness
Between ground and CP02 (female) (109) or R02 (fe-
Resistance Min. 1 MΩ
male) (1)
Defective machine con- If no failure is found by preceding checks, work equipment controller is defective.
3
troller (Since this is an internal defect, troubleshooting cannot be performed.)

40-178 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING FAILURE CODE [DKULKB]

Circuit diagram related to PPC lock switch

PC45MR-5, PC55MR-5 40-179

FAILURE CODE [DKULKY] 40 TROUBLESHOOTING

FAILURE CODE [DKULKY]

Action level Failure code Proportional Pressure Control Lock Relay Hot Short Circuit
Failure
L03 DKULKY (Machine controller system)
Detail of fail- Hot short circuit is detected in the circuit when output to PPC lock relay (coil side) is stopped (during
ure lock lever automatic lock control).
Action of • None in particular.
controller • If cause of failure disappears, machine becomes normal by itself.
Phenomenon When the lock lever is unlocked while the work equipment control lever or the travel lever is operat-
on machine ed, the lock lever automatic lock system does not function.

Related After completion of repair, check if the failure code is cleared by the following procedure.
information Procedure: Start the engine, and lock the lock lever.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
Hot short circuit in wiring 2. Disconnect relay R02, and connect T-adapter to female side.
1
harness 3. Turn the starting switch to ON position.
Voltage Between R02 (female) (1) and ground Max. 4.5 V
Defective machine con- If no failure is found by preceding checks, work equipment controller is defective.
2
troller (Since this is an internal defect, troubleshooting cannot be performed.)

40-180 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING FAILURE CODE [DKULKY]

Circuit diagram related to PPC lock switch

PC45MR-5, PC55MR-5 40-181

FAILURE CODE [DV00KB] 40 TROUBLESHOOTING

FAILURE CODE [DV00KB]

Action level Failure code Buzzer Output Short Circuit
Failure
L01 DV00KB (Machine monitor system)
Detail of fail-
Unusual current flows when power is output to alarm buzzer circuit.
ure
• Stops outputting power to alarm buzzer circuit.
Action of
• Even if cause of failure disappears, machine does not become normal until starting switch
controller
is turned to OFF position.
Phenomenon
Alarm buzzer does not sound.
on machine
Related
No
information

No. Cause Procedure, measuring location, criteria and remarks

Defective machine moni- Defective machine monitor (Because this is an internal defect, troubleshooting can-
1
tor not be performed.)

40-182 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING FAILURE CODE [DV20KB]

FAILURE CODE [DV20KB]

Action level Failure code Travel Alarm Short Circuit
Failure
L01 DV20KB (Machine controller system)
Detail of fail-
Abnormal current flows when driving the travel alarm circuit.
ure
• Stops driving the travel alarm circuit.
Action of
• Even if cause of failure disappears, machine does not become normal until starting switch
controller
is set to OFF position.
Phenomenon
Travel alarm does not sound.
on machine
Related As T-adapter for machine controller connector is “socket-type box”, operating voltage cannot be
information measured at machine controller connector.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect connector M08, and connect T-adapter to female side.
3. Turn the starting switch to ON position.
4. Perform troubleshooting by control of travel lever.
k When driving machine, do not measure under the machine.
Defective travel alarm REMARK
1
(Internal defect) • When travel lever is set to the travel position, voltage is applied usually to
the travel alarm connector before machine moves off.
• If the following voltage is normal but travel alarm does not sound, travel
alarm is defective.

Between M08 (female) (1) Travel lever: Neutral Max. 1 V

Voltage
and (2) Travel lever: Operated 10 to 15 V
1. Turn the starting switch to OFF position.
Ground fault in wiring
2. Disconnect connectors CP02 and M08, and connect T-adapter to either fe-
harness
2 male side.
(Contact with ground cir-
cuit) Between CP02 (female) (86) and ground, or M08 (fe-
Resistance Min. 1 MΩ
male) (1) and ground
1. Turn the starting switch to OFF position.
2. Disconnect connector M08, and connect T-adapter to female side.
3. Turn the starting switch to ON position.
Defective machine con- 4. Perform troubleshooting by control of travel lever.
3
troller
k When driving machine, do not measure under the machine.

Between M08 (female) (1) Travel lever: Neutral Max. 1 V

Voltage
and (2) Travel lever: Operated 10 to 15 V

PC45MR-5, PC55MR-5 40-183

FAILURE CODE [DV20KB] 40 TROUBLESHOOTING

Circuit diagram related to travel alarm

40-184 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING FAILURE CODE [DW43KA]

FAILURE CODE [DW43KA]

Action level Failure code Travel Speed Solenoid Open Circuit
Failure
L01 DW43KA (Machine controller system)
Detail of fail- When controller does not drive travel speed selector solenoid, output terminal voltage of controller is
ure higher than specified value.
Action of • None in particular (Since no current flows, solenoid is not energized.)
controller • If cause of failure disappears, machine becomes normal by itself.
Phenomenon Machine travels slow in Hi travel speed setting (machine monitor shows Hi setting but the speed is
on machine kept at around Lo).

• Controller's command (ON/OFF) to travel speed selector solenoid can be checked with
monitoring function. (As long as controller's command to solenoid is ON, indication on
Related
monitoring is ON even if solenoid is not energized due to open circuit.) (Code: 02300)
information
• After completion of repair, check if the failure code is cleared by the following procedure.
Procedure: Turn the starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

Defective travel speed 1. Turn the starting switch to OFF position.

1 selector solenoid 2. Disconnect connector M17, and connect T-adapter to male side.
(Internal open circuit) Resistance Between M17 (male) (1) and (2) 8 to 15 Ω
1. Turn the starting switch to OFF position.
2. Disconnect connector M17, and connect T-adapter to female side.
Open circuit, short circuit,
3. Turn the starting switch to ON position.
ground fault, hot short
2 circuit of wiring harness, REMARK
or defective machine
controller Shake the wiring harness by hand while measuring the voltage. If the voltage be-
comes 0 V while shaking, wiring harness has open circuit.
Voltage Between M17 (female) (1) and (2) 1.9 to 7 V
If no failure is found by check on cause 2, this check is not required.
1. Turn the starting switch to OFF position.
Open circuit or short cir-
3 2. Disconnect connector CP02 and connect T-adapter to female side.
cuit in wiring harness
Between CP02 (female) (107) and each of (114), (115),
Resistance 8 to 15 Ω
(117), and (120)
If no failure is found by check on cause 2, this check is not required.
1. Turn the starting switch to OFF position.
Open circuit in wiring har- 2.
Disconnect connectors CP02 and M17, and connect T-adapters to each
ness
4 female side.
(Wire breakage or defec-
tive contact of connector) Between CP02 (female) (107) and M17 (female) (1) Max. 1 Ω
Resistance Between M17 (female) (2) and each of CP02 (female)
Max. 1 Ω
(114), (115), (117), and (120)
Defective machine con- If no failure is found by preceding checks, work equipment controller is defective.
5
troller (Since this is an internal defect, troubleshooting cannot be performed.)

PC45MR-5, PC55MR-5 40-185

FAILURE CODE [DW43KA] 40 TROUBLESHOOTING

Circuit diagram related to travel Hi/Lo solenoid

40-186 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING FAILURE CODE [DW43KB]

FAILURE CODE [DW43KB]

Action level Failure code Travel Speed Solenoid Short Circuit
Failure
L01 DW43KB (Machine controller system)
Detail of fail- Abnormal current flows when pump controller drives travel speed solenoid, so pump controller de-
ure termines that short circuit exists in travel speed solenoid circuit.
• Stops driving travel speed solenoid.
Action of
• Even if cause of failure disappears, machine does not become normal until starting switch
controller
is turned to OFF position.
Phenomenon Machine travels slow in Hi travel speed setting (machine monitor shows Hi setting but the speed is
on machine kept at around Lo).

• Controller's command (ON/OFF) to travel speed selector solenoid can be checked with
monitoring function. (As long as controller's command to solenoid is ON, indication on
Related
monitoring is ON even if solenoid is not energized due to short circuit.) (Code: 02300)
information
• After completion of repair, check if the failure code is cleared by the following procedure.
Procedure: Turn the starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
Defective travel speed
selector solenoid 2. Disconnect connector M17, and connect T-adapter to male side.
1
(Internal short circuit or Between M17 (male) (1) and (2) 8 to 15 Ω
ground fault) Resistance
Between M17 (male) (1) and ground Min. 1 MΩ
1. Turn the starting switch to OFF position.
2. Disconnect connector CP02 and connect T-adapter to female side.
Short circuit or ground
2 Between CP02 (female) (107) and each of (114), (115),
fault in wiring harness 8 to 15 Ω
Resistance (117), and (120)
Between CP02 (female) (107) and ground Min. 1 MΩ
If no failure is found by check on cause 2, this check is not required.
Ground fault in wiring 1. Turn the starting switch to OFF position.
harness 2. Disconnect connectors CP02 and M17, and connect T-adapter to either fe-
3
(Contact with ground cir- male side.
cuit)
Between ground and CP02 (female) (107) or M17 (fe-
Resistance Min. 1 MΩ
male) (1)
Defective machine con- If no failure is found by preceding checks, work equipment controller is defective.
4
troller (Since this is an internal defect, troubleshooting cannot be performed.)

PC45MR-5, PC55MR-5 40-187

FAILURE CODE [DW43KB] 40 TROUBLESHOOTING

Circuit diagram related to travel Hi/Lo solenoid

40-188 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING FAILURE CODE [DW43KY]

FAILURE CODE [DW43KY]

Action level Failure code Travel Speed Solenoid Hot Short Circuit
Failure
L01 DW43KY (Machine controller system)
Detail of fail- When controller does not drive travel speed selector solenoid, output terminal voltage of controller is
ure higher than specified value, and hot short circuit is detected.
Action of • None in particular
controller • If cause of failure disappears, machine becomes normal by itself.
Phenomenon Machine travels fast in Lo travel speed setting (machine monitor shows Lo setting but the speed is
on machine kept at around Hi).

• Controller's command (ON/OFF) to travel speed selector solenoid can be checked with
monitoring function. (As long as controller's command to solenoid is OFF, sensor state dis-
Related played on monitoring screen is OFF even if solenoid is not energized due to hot short cir-
information cuit.) (Code: 02300)
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
Hot short circuit in wiring 2. Disconnect connector M17, and connect T-adapter to female side.
1
harness 3. Turn the starting switch to ON position.
Voltage Between M17 (female) (1) and ground Max. 4.5 V
Defective machine con- If no failure is found by preceding checks, work equipment controller is defective.
2
troller (Since this is an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to travel Hi/Lo solenoid

PC45MR-5, PC55MR-5 40-189

FAILURE CODE [DW4CKY] 40 TROUBLESHOOTING

FAILURE CODE [DW4CKY]

Action level Failure code PPC Lock Solenoid Hot Short Circuit
Failure
L03 DW4CKY (Machine controller system)

Details of
5.2 V or higher is detected in PPC lock solenoid circuit during lock lever automatic lock.
failure
Action of • None in particular
controller • If cause of failure disappears, machine becomes normal by itself.
Phenomenon
Lock cannot be engaged by using lock lever.
on machine
Related After repairing, check if the failure code is cleared by the following procedure.
information Procedure: Start the engine and lock the lock lever.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
Hot short circuit in wiring 2. Disconnect connector M18, and connect T-adapter to female side.
1
harness 3. Turn the starting switch to ON position.
Voltage Between M18 (female) (1) and ground Max.4.5 V
Defective machine con- If no failure is found by preceding checks, work equipment controller is defective.
2
troller (Since this is an internal defect, troubleshooting cannot be performed.)

40-190 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING FAILURE CODE [DW4CKY]

Circuit diagram related to PPC lock switch

PC45MR-5, PC55MR-5 40-191

FAILURE CODE [DXA8KA] 40 TROUBLESHOOTING

FAILURE CODE [DXA8KA]

Action level Failure code Pump PC-EPC Solenoid Open Circuit
Failure
L03 DXA8KA (Machine controller system)
Detail of fail- No current flows when pump controller drives pump PC-EPC solenoid, so pump controller deter-
ure mines that open circuit exists in pump PC-EPC solenoid circuit.
Action of • None in particular (Since no current flows, solenoid is not energized.)
controller • If cause of failure disappears, machine becomes normal by itself.
Phenomenon
If pump load increases, engine speed decreases largely and engine may stop.
on machine
• When solenoid and wiring harness are normal, engine can be prevented from stopping by
setting pump drive secondary switch to ON position.
Related • Drive current of pump PC-EPC solenoid can be checked with monitoring function.
information (Code: 01300)
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

Wrong operation of pump Toggle the pump drive secondary switch to normal (lower) position.
1
secondary drive switch

Defective PC-EPC sole- 1. Turn starting switch to OFF position.

2 noid 2. Disconnect connector M11, and connect T-adapter to male side.
(Internal open circuit) Resistance Between M11 (male) (1) and (2) 3 to 14 Ω
1. Turn starting switch to OFF position.
Open circuit, short circuit, 2. Disconnect connector M11, and connect T-adapter to female side.
ground fault, hot short 3. Turn starting switch to ON position.
3 circuit of wiring harness,
or defective machine 4. Shake the wiring harness by hand while measuring the voltage. If the volt-
controller age becomes 0 V while shaking, wiring harness is open.
Voltage Between M11 (female) (1) and (2) Min. 10 V
1. Turn starting switch to OFF position.
2. Disconnect connector S25 and connect T-adapter to male side.
Defective pump secon- Switch position: Normal Max. 1 Ω
dary drive switch Between S25 (male) (3)
4
and (2) Switch position: Drive Min. 1 MΩ
(Internal open circuit) Resistance
Between S25 (male) (6) Switch position: Normal Max. 1 Ω
and (5) Switch position: Drive Min. 1 MΩ
1. Turn starting switch to OFF position.
2. Disconnect connector CP02 and connect T-adapter to female side.
Open or short circuit in
5 Check that pump drive secondary switch is in the normal position (lower).
wiring harness
Between CP02 (female) (102) and each of (114), (115),
Resistance 3 to 14 Ω
(117), and (120)

40-192 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING FAILURE CODE [DXA8KA]

No. Cause Procedure, measuring location, criteria and remarks

If failure code is still displayed after above checks on cause 3, this check is not re-
quired.
1. Turn starting switch to OFF position.
2. Disconnect connectors CP02, S25 and M11, and connect T-adapters to
Open circuit in wiring har-
each female side.
ness
6 Between CP02 (female) (102) and S25 (female) (3) Max. 1 Ω
(Wire breakage or defec-
tive contact of connector) Between S25 (female) (2) and M11 (female) (1) Max. 1 Ω
Resistance Between S25 (female) (6) and each of CP02 (female)
Max. 1 Ω
(114), (115), (117), (120)
Between S25 (female) (5) and M11 (female) (2) Max. 1 Ω
Defective machine con- If no failure is found by preceding checks, work equipment controller is defective.
7
troller (Since this is an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to PC-EPC solenoid system

PC45MR-5, PC55MR-5 40-193

FAILURE CODE [DXA8KB] 40 TROUBLESHOOTING

FAILURE CODE [DXA8KB]

Action level Failure code Pump PC-EPC Solenoid Short Circuit
Failure
L03 DXA8KB (Machine controller system)
Detail of fail- Abnormal current flows when pump controller drives pump PC-EPC solenoid, so pump controller
ure determines that short circuit exists in pump PC-EPC solenoid circuit.
Stops output to pump PC-EPC solenoid.
Action of
Even if cause of failure disappears, machine does not become normal until starting switch is turned
controller
to OFF position.
Phenomenon
If pump load increases, engine speed decreases largely and engine may stop.
on machine
• When solenoid and wiring harness are normal, engine can be prevented from stopping by
setting pump drive secondary switch to ON position.
Related • Drive current of pump PC-EPC solenoid can be checked with monitoring function.
information (Code: 01300)
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Defective PC-EPC sole-
noid 2. Disconnect connector M11, and connect T-adapter to male side.
1
(Internal short circuit or Between M11 (male) (1) and (2) 3 to 14 Ω
ground fault) Resistance
Between M11 (male) (1) and ground Min. 1 MΩ
1. Turn starting switch to OFF position.
2. Disconnect connector S25 and connect T-adapter to male side.

Defective pump secon- Between S25 (male) (2)

2 dary drive switch (internal and (5), or between S25 Switch position: Normal Min. 1 MΩ
short circuit, ground fault) (male) (3) and (5)
Resistance
Between S25 (male) (2)
and ground, or between Switch position: Normal Min. 1 MΩ
S25 (male) (3) and ground
1. Turn starting switch to OFF position.
2. Disconnect connector CP02 and connect T-adapter to female side.
Short circuit or ground Check that pump drive secondary switch is in the normal position (lower).
3
fault in wiring harness Between CP02 (female) (102) and each of (114), (115),
3 to 14 Ω
Resistance (117), and (120)
Between CP02 (female) (102) and ground Min. 1 MΩ
If failure code is still displayed after above checks on cause 3, this check is not re-
quired.
1. Turn starting switch to OFF position.
Ground fault in wiring 2. Disconnect connectors CP02, S25 and M11, and connect T-adapter to any
harness
4 female side.
(Contact with ground cir-
cuit) Between ground and CP02 (female) (102) or S25 (fe-
Min. 1 MΩ
male) (3)
Resistance
Between ground and S25 (female) (2) or M11 (female)
Min. 1 MΩ
(1)

40-194 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING FAILURE CODE [DXA8KB]

No. Cause Procedure, measuring location, criteria and remarks

Defective machine con- If no failure is found by preceding checks, work equipment controller is defective.
5
troller (Since this is an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to PC-EPC solenoid system

PC45MR-5, PC55MR-5 40-195

FAILURE CODE [DXE7KA] 40 TROUBLESHOOTING

FAILURE CODE [DXE7KA]

Action level Failure code Attachment Flow Regulating EPC 2 Solenoid Open Circuit
Failure
- DXE7KA (Machine controller system)
Detail of fail- When attachment flow rate adjustment EPC2 solenoid is driven, no current flows in the circuit, so
ure the open circuit is detected.
• Stops driving attachment flow rate adjustment EPC2 solenoids.
Action of • Also sets output command to attachment flow rate adjustment EPC5 solenoid to 0 mA.
controller • Even if cause of failure disappears, machine does not become normal until starting switch
is turned to OFF position.
Phenomenon
Attachment does not move.
on machine
• Drive current of attachment flow rate adjustment EPC2 solenoid can be checked with
monitoring function (code: 01702).
Related
• After repairing, check if the failure code is cleared by the following procedure.
information
Procedure: Turn the starting switch to ON position and set machine in attachment mode
(ATT).

No. Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Defective attachment
1 flow rate adjustment EPC 2. Disconnect connector V02, and connect T-adapter to male side.
2 (internal open circuit)
Resistance Between V02 (male) (1) and (2) 3 to 15 Ω
1. Turn starting switch to OFF position.
2. Disconnect connectors CP02 and V02, and connect T-adapters to each fe-
Open circuit in wiring har- male side.
2
ness Between CP02 (female) (103) and V02 (female) (2) Max. 1 Ω
Resistance Between each of CP02 (female) (114), (115), (117),
Max. 1 Ω
(120) and V02 (female) (1)
Defective machine con- If no failure is found by preceding checks, work equipment controller is defective.
3
troller (Since this is an internal defect, troubleshooting cannot be performed.)

40-196 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING FAILURE CODE [DXE7KA]

Circuit diagram related to ATT flow rate adjustment EPC

PC45MR-5, PC55MR-5 40-197

FAILURE CODE [DXE7KB] 40 TROUBLESHOOTING

FAILURE CODE [DXE7KB]

Action level Failure code Attachment Flow Regulating EPC 2 Solenoid Short Circuit
Failure
- DXE7KB (Machine controller system)
Abnormal current flows when pump controller drives attachment flow rate (service current) EPC2
Detail of fail-
solenoid, so pump controller determines that short circuit exists in attachment flow rate adjustment
ure
(service current) EPC2 solenoid circuit.
• Stops driving attachment flow rate adjustment EPC2 solenoids.
Action of • Also sets output command to attachment flow rate adjustment EPC5 solenoid to 0 mA.
controller • Even if cause of failure disappears, machine does not become normal until starting switch
is turned to OFF position.
Phenomenon
Attachment does not move.
on machine
• Drive current of attachment flow rate adjustment EPC2 solenoid can be checked with
monitoring function (code: 01702).
Related
• After repairing, check if the failure code is cleared by the following procedure.
information
Procedure: Turn the starting switch to ON position and set machine in attachment mode
(ATT).

No. Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Defective attachment
2. Disconnect connector V02, and connect T-adapter to male side.
flow rate adjustment EPC
1
2 (internal short circuit or Between V02 (male) (1) and (2) 3 to 15 Ω
ground fault) Resistance
Between V02 (male) (2) and ground Min. 1 MΩ
1. Turn starting switch to OFF position.
Ground fault in wiring 2. Disconnect connectors CP02 and V02, and connect T-adapters to each fe-
2 harness (contact with male side.
ground circuit)
Between ground and CP02 (female) (103) or V02 (fe-
Resistance Min. 1 MΩ
male) (2)
Defective machine con- If no failure is found by preceding checks, work equipment controller is defective.
3
troller (Since this is an internal defect, troubleshooting cannot be performed.)

40-198 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING FAILURE CODE [DXE7KB]

Circuit diagram related to ATT flow rate adjustment EPC

PC45MR-5, PC55MR-5 40-199

FAILURE CODE [DXE7KY] 40 TROUBLESHOOTING

FAILURE CODE [DXE7KY]

Action level Failure code Attachment Flow Regulating EPC 2 Hot Short Circuit
Failure
- DXE7KY (Machine controller system)
Detail of fail-
Current flows when driving attachment flow rate adjustment EPC2 solenoid circuit stops.
ure
• Stops driving attachment flow rate adjustment EPC2 solenoids.
Action of • Also sets output command to attachment flow rate adjustment EPC5 solenoid to 0 mA.
controller • Even if cause of failure disappears, machine does not become normal until starting switch
is turned to OFF position.
Phenomenon
Attachment does not move.
on machine
• Drive current of attachment flow rate adjustment EPC2 solenoid can be checked with
monitoring function (code: 01702).
Related
• After repairing, check if the failure code is cleared by the following procedure.
information
Procedure: Turn the starting switch to ON position and set machine in attachment mode
(ATT).

No. Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Defective attachment
2. Disconnect connector V02, and connect T-adapter to male side.
flow rate adjustment EPC
1
2 (internal short circuit or Between V02 (male) (1) and (2) 3 to 15 Ω
ground fault) Resistance
Between V02 (male) (2) and ground Min. 1 MΩ
1. Turn starting switch to OFF position.
Hot short circuit in wiring 2. Disconnect connector V02, and connect T-adapter to female side.
2
harness 3. Turn starting switch to ON position.
Voltage Between V02 (female) (2) and ground Max. 4.5 V
Defective machine con- If no failure is found by preceding checks, work equipment controller is defective.
3
troller (Since this is an internal defect, troubleshooting cannot be performed.)

40-200 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING FAILURE CODE [DXE7KY]

Circuit diagram related to ATT flow rate adjustment EPC

PC45MR-5, PC55MR-5 40-201

FAILURE CODE [DXEAKA] 40 TROUBLESHOOTING

FAILURE CODE [DXEAKA]

Action level Failure code Attachment Flow Regulating EPC 5 Solenoid Open Circuit
Failure
- DXEAKA (Machine controller system)
Detail of fail- When attachment flow rate adjustment EPC5 solenoid is driven, no current flows in the circuit, so
ure the open circuit is detected.
• Stops driving attachment flow rate adjustment EPC5 solenoids.
Action of • Also sets output command to attachment flow rate adjustment EPC2 solenoid to 0 mA.
controller • Even if cause of failure disappears, machine does not become normal until starting switch
is turned to OFF position.
Phenomenon
Attachment does not move.
on machine
• Drive current of attachment flow rate adjustment EPC5 solenoid can be checked with
monitoring function (code: 01701).
Related
• After repairing, check if the failure code is cleared by the following procedure.
information
Procedure: Turn the starting switch to ON position and set machine in attachment mode
(ATT).

No. Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Defective attachment
1 flow rate adjustment EPC 2. Disconnect connector V01, and connect T-adapter to male side.
5 (internal open circuit)
Resistance Between V01 (male) (1) and (2) 3 to 15 Ω
1. Turn starting switch to OFF position.
2. Disconnect connectors CP02 and V01, and connect T-adapters to each fe-
Open circuit in wiring har- male side.
2
ness Between CP02 (female) (111) and V01 (female) (2) Max. 1 Ω
Resistance Between each of CP02 (female) (114), (115), (117),
Max. 1 Ω
(120) and V01 (female) (1)
Defective machine con- If no failure is found by preceding checks, work equipment controller is defective.
3
troller (Since this is an internal defect, troubleshooting cannot be performed.)

40-202 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING FAILURE CODE [DXEAKA]

Circuit diagram related to ATT flow rate adjustment EPC

PC45MR-5, PC55MR-5 40-203

FAILURE CODE [DXEAKB] 40 TROUBLESHOOTING

FAILURE CODE [DXEAKB]

Action level Failure code Attachment Flow Regulating EPC 5 Solenoid Short Circuit
Failure
- DXEAKB (Machine controller system)
Detail of fail- Abnormal current flows when driving attachment flow rate (service current) EPC5 solenoid, so short
ure circuit is detected.
• Stops driving attachment flow rate adjustment EPC5 solenoids.
Action of • Also sets output command to attachment flow rate adjustment EPC2 solenoid to 0 mA.
controller • Even if cause of failure disappears, machine does not become normal until starting switch
is turned to OFF position.
Phenomenon
Attachment does not move.
on machine
• Drive current of attachment flow rate adjustment EPC5 solenoid can be checked with
monitoring function (code: 01701).
Related
• After repairing, check if the failure code is cleared by the following procedure.
information
Procedure: Turn the starting switch to ON position and set machine in attachment mode
(ATT).

No. Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Defective attachment
2. Disconnect connector V01, and connect T-adapter to male side.
flow rate adjustment EPC
1
5 (internal short circuit or Between V01 (male) (1) and (2) 3 to 15 Ω
ground fault) Resistance
Between V01 (male) (2) and ground Min. 1 MΩ
1. Turn starting switch to OFF position.
Ground fault in wiring 2. Disconnect connectors CP02 and V01, and connect T-adapters to each fe-
2 harness (contact with male side.
ground circuit)
Between ground and CP02 (female) (111) or V01 (fe-
Resistance Min. 1 MΩ
male) (2)
Defective machine con- If no failure is found by preceding checks, work equipment controller is defective.
3
troller (Since this is an internal defect, troubleshooting cannot be performed.)

40-204 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING FAILURE CODE [DXEAKB]

Circuit diagram related to ATT flow rate adjustment EPC

PC45MR-5, PC55MR-5 40-205

FAILURE CODE [DXEAKY] 40 TROUBLESHOOTING

FAILURE CODE [DXEAKY]

Action level Failure code Attachment Flow Regulating EPC 5 Hot Short Circuit
Failure
- DXEAKY (Machine controller system)
Detail of fail-
Current flows when driving attachment flow rate adjustment EPC5 solenoid circuit stops.
ure
• Stops driving attachment flow rate adjustment EPC5 solenoids.
Action of • Also sets output command to attachment flow rate adjustment EPC2 solenoid to 0 mA.
controller • Even if cause of failure disappears, machine does not become normal until starting switch
is turned to OFF position.
Phenomenon
Attachment does not move.
on machine
• Drive current of attachment flow rate adjustment EPC5 solenoid can be checked with
monitoring function (code: 01701).
Related
• After repairing, check if the failure code is cleared by the following procedure.
information
Procedure: Turn the starting switch to ON position and set machine in attachment mode
(ATT).

No. Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Defective attachment
2. Disconnect connector V01, and connect T-adapter to male side.
flow rate adjustment EPC
1
5 (internal short circuit or Between V01 (male) (1) and (2) 3 to 15 Ω
ground fault) Resistance
Between V01 (male) (2) and ground Min. 1 MΩ
1. Turn starting switch to OFF position.
Hot short circuit in wiring 2. Disconnect connector V01, and connect T-adapter to female side.
2
harness 3. Turn starting switch to ON position.
Voltage Between V01 (female) (2) and ground Max. 4.5 V
Defective machine con- If no failure is found by preceding checks, work equipment controller is defective.
3
troller (Since this is an internal defect, troubleshooting cannot be performed.)

40-206 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING FAILURE CODE [DXEAKY]

Circuit diagram related to ATT flow rate adjustment EPC

PC45MR-5, PC55MR-5 40-207

E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) 40 TROUBLESHOOTING

TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-

MODE)
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK)
Failure Engine does not start (engine does not crank)
• The engine start circuit is equipped with the start lock function of the following two sys-
tems.
1. Start lock by password of machine monitor
Related infor- 2. Start lock by lock lever
mation
• If failure symptom machine monitor does not light up is displayed while starting switch is
turned to ON position, main power supply system may be defective. Perform troubleshoot-
ing for E-mode “WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE
MONITOR DISPLAYS NOTHING”.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
Loose terminal or open
1 Check terminals of starting motor, alternator, and ground terminals T01, T02, T03,
circuit in terminal
etc.
Check battery voltage and specific gravity of battery electrolyte.

Insufficient battery ca- Battery voltage (per 1 cell) Min. 12 V

2
pacity Battery voltage (2cells in-line) Min. 24 V
Gravity of battery Min. 1.26
Defective engine control- As for engine controller power supply and ACC signal, perform troubleshooting for
3
ler system causes 1 and 2 of failure code [DB2QKR] first.
If fuse No.3 in fuse box FB1 is blown out, circuit probably has ground fault. (See
4 Defective fuse
ground fault (contact to ground circuit) of wiring harness.)
• If fusible link M09 is burnt out, circuit probably has ground fault. In this
case, perform troubleshooting for ground fault of wiring harness in cause
13 first.
5 Defective fusible link • Fusible link M09 is connected to fuses No.1 to 10 and has large scale of
circuits connected. Accordingly, if no failure is found by check on cause 13,
reproduce the phenomenon to locate the ground fault place by unusual
noise and burnt smell so that the trouble can be resolved earlier.
If slow-blow fuse (TM15) is blown out, circuit probably has ground fault, etc. (See
6 Defective slow-blow fuse
check on cause of wiring harness ground fault.)
1. Turn the starting switch to OFF position.
2. Remove fuse No.14 in fuse box FB1 (to prevent engine from starting dur-
ing check).
3. Insert checker harness into connector CE1.
Defective starting switch,
lock lever switch, starting 4. Turn the starting switch to START position and hold it (2 persons required
7 motor cut-off relay, per- for this work).
sonal code relay, and wir-
ing harness REMARK
For checker harness, see Engine Shop Manual.
Voltage Between CE1 (35) and ground 10 to 15 V
If voltage is abnormal, go to check on cause 8.

40-208 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK)

No. Cause Procedure, measuring location, criteria and remarks

If check on cause 7 is normal, this check is not required.
1. Turn starting switch to OFF position.
2. Turn battery disconnect switch to OFF position.
Turn starting switch to
Min. 1 MΩ
OFF position.
Defective starting switch Between TF1 and TF3
8 Turn starting switch to ON
(internal open circuit) Max. 1 Ω
position.
Resistance
Turn starting switch to
Min. 1 MΩ
OFF position.
Between TF1 and TF4
Turn starting switch to
Max. 1 Ω
START position.
If no failure is found on cause 7, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connector F09 and connect T-adapter to female side.
Defective lock lever
9 Between F09 (female) (A)
switch Lock lever: FREE Min. 1 MΩ
and (C)
Resistance
Between F09 (female) (A)
Lock lever: LOCK Max. 1 Ω
and (C)
If check on cause 7 is normal, this check is not required.
1. Turn starting switch to OFF position.

Defective starting motor 2. Replace the starting motor cut-off relay R01 with the light relay R04.
10
cut-off relay 3. Turn starting switch to ON position.
If the engine can be started, the original starting motor cut-off relay R01 is defec-
tive.
If no failure is found on cause 7, this check is not required.
1. Turn the starting switch to OFF position.
Defective personal code 2. Replace personal code relay R06 with light relay R04.
11
relay
3. Turn the starting switch to ON position.
If the engine can start, the original personal code relay R06 is defective.

PC45MR-5, PC55MR-5 40-209

E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

If no failure is found by check on cause 7, this check is not required.
1. Turn the starting switch to OFF position.
2. Disconnect the battery ground, or turn the battery disconnect switch to OFF
position.
(to avoid short circuit during check)
3. Disconnect fusible link M09 and fuse FB1 (3).
4. Connect T-adapter to male side of connector M09.
Between battery (+) terminal and M09 (male) (2) Max. 1 Ω
Resistance
Between M09 (male) (1) and TF1 Max. 1 Ω
If no failure is found by check on cause 7, this check is not required.
1. Turn the starting switch to OFF position.
2. Disconnect connectors F09, R01, R06, F15, and CE1.
Open circuit in wiring har-
ness 1 (wire breakage or 3. Connect T-adapter to each female sides of F09, R01, R06, F15, CE1, and
12
defective contact of con- male side of F09.
nector) 4. Remove fuse FB1 (3).
Between TF3 and FB1 (1A) Max. 1 Ω
Between FB1 (3) and F09 (male) (A) Max. 1 Ω
Between F09 (male) (C) and R01 (female) (1) Max. 1 Ω
Between R01 (female) (2) and ground Max. 1 Ω
Resistance Between FB1 (3) and R06 (female) (1) Max. 1 Ω
Between R06 (female) (2) and F15 (female) (4) Max. 1 Ω
Between TF4 and R01 (female) (3) Max. 1 Ω
Between R01 (female) (5) and R06 (female) (3) Max. 1 Ω
Between R06 (female) (4) and CE1 (female) (35) Max. 1 Ω

40-210 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK)

No. Cause Procedure, measuring location, criteria and remarks

If no failure is found by check on cause 7, this check is not required.
1. Turn the starting switch to OFF position.
2. Disconnect the battery ground, or turn the battery disconnect switch to OFF
position.
(to avoid short circuit during check)
3. Disconnect fusible link M09 and fuse FB1 (3).
4. Connect T-adapter to male side of connector M09.
Between ground and battery (+) terminal or M09
Min. 1 MΩ
(male) (2)
Resistance
Between ground and M09 (male) (1) or TF1 Min. 1 MΩ
Between ground and TF3 or FB1 (1A) Min. 1 MΩ
If no failure is found by check on cause 7, this check is not required.
1. Turn the starting switch to OFF position.
2. Disconnect the battery ground, or turn the battery disconnect switch to OFF
Ground fault in wiring
position.
13 harness 1 (contact with
ground circuit) 3. Disconnect connectors F09, R01, R06, F15, and CE1.
4. Connect T-adapter to each female sides of F09, R01, R06, F15, CE1, and
male side of F09.
5. Remove fuse FB1 (3).
Between ground and TF3 or FB1 (1A) Min. 1 MΩ
Between ground and FB1 (3) or F09 (male) (A) or R06
Min. 1 MΩ
(female) (1)
Between ground and R06 (female) (2) or F15 (female)
Min. 1 MΩ
(4)
Resistance
Between ground and TF4 or R01 (female) (3) Min. 1 MΩ
Between ground and R01 (female) (5) or R06 (female)
Min. 1 MΩ
(3)
Between ground and R06 (female) (4) or CE1 (female)
Min. 1 MΩ
(35)
1. Turn the starting switch to OFF position.
Defective starting motor 2. Replace starter relay M16 with glow plug relay M13.
14
relay 3. Turn the starting switch to ON position.
If the engine can be started, the original starter relay M16 is defective.
1. Turn starting switch to OFF position.
Defective alternator (in- 2.
15 Turn starting switch to START position to perform troubleshooting.
ternal short circuit)
Voltage Between M10 (1) and ground Max. 1 V

PC45MR-5, PC55MR-5 40-211

E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Turn starting switch to START position to perform troubleshooting.
Between starting motor
terminal B (TM16) and Power supply 10 to 15 V
ground
16 Defective starting motor Voltage
Between starting motor
terminal S (TM6) and Input for starting 10 to 15 V
ground
If power supply and start input are normal but the starting motor does not rotate,
the starting motor is defective.

REMARK
If fuse or fusible link is burnt out, replace it.
1. Turn the starting switch to OFF position.
2. Disconnect the battery ground, or turn the battery disconnect switch to OFF
position.
3. Disconnect connector M16.
4. Connect T-adapter to female side of CE1.
Open circuit in wiring har-
ness 2 (wire breakage or Between TM1 and starting motor B terminal (TM16) Max. 1 Ω
17
defective contact of con-
Between starting motor B terminal (TM16) and alterna-
nector) Max. 1 Ω
tor B terminal (TM2)
Between alternator B terminal (TM2) and M16 (female)
Max. 1 Ω
Resistance (1)
Between M16 (female) (4) and starting motor S termi-
Max. 1 Ω
nal (TM6)
Between CE1 (female) (73) and M16 (female) (2) Max. 1 Ω
Between M16 (female) (3) and CE1 (female) (28) Max. 1 Ω
1. Turn the starting switch to OFF position.
2. Disconnect the battery ground, or turn the battery disconnect switch to OFF
position.
3. Disconnect connectors F09, R01, R06, F15, and CE1.
4. Connect T-adapter to each female sides of F09, R01, R06, F15, CE1, and
Ground fault in wiring male side of F09.
18 harness 2 (contact with 5. Remove fuse FB1 (3).
ground circuit)
Between ground and starting motor B terminal (TM16)
Min. 1 MΩ
or alternator B terminal (TM2) or M16 (female) (1)
Between ground and M16 (female) (4) or starting mo-
Resistance Min. 1 MΩ
tor S terminal (TM6)
Between ground and M16 (female) (2) or CE1 (female)
Min. 1 MΩ
(73)

40-212 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK)

Circuit diagram related to engine starting circuit

PC45MR-5, PC55MR-5 40-213

E-2 ENGINE DOES NOT START (FUEL FEED PUMP SYSTEM) 40 TROUBLESHOOTING

E-2 ENGINE DOES NOT START (FUEL FEED PUMP SYSTEM)

Failure Engine does not start (fuel feed pump system).
Related infor-
When engine cranks
mation

No. Cause Procedure, measuring location, criteria and remarks

1 Defective fuse If fuse No.5 in fuse box FB1 is blown out, circuit probably has ground fault, etc.
1. Turn the starting switch to OFF position.
2. Connect T-adapter to connector M14.
Approx.
Resistance Between M14 (male) (1) and (2)
140 Ω
2 Defective fuel feed pump
1. Turn the starting switch to OFF position.
2. Disconnect fuel hose at outlet side.
3. Turn the starting switch to ON position.
Fuel flows out.
1. Turn the starting switch to OFF position.
Open circuit in wiring har-
2. Disconnect connectors M14, and connect T-adapter to female side of M14.
ness (wire breakage or
3
defective contact of con- Between FB1(5) and M14 (female) (2) Max. 1 Ω
nector) Resistance
Between ground and M14 (female) (1) Max. 1 Ω
1. Turn the starting switch to OFF position.
Ground fault in wiring
4 harness (contact with 2. Disconnect connectors M14, and connect T-adapter to female side of M14.
ground circuit)
Resistance Between ground and FB1(5) or M14 (female) (2) Min. 1 MΩ

40-214 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING E-2 ENGINE DOES NOT START (FUEL FEED PUMP SYSTEM)

CIRCUIT DIAGRAM (ELECTRIC FUEL FEED PUMP SWITCH)

PC45MR-5, PC55MR-5 40-215

E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK 40 TROUBLESHOOTING

E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK

Failure Automatic preheating system does not work.
• Automatic preheating starts when engine coolant temperature is below +5 °C.
(Monitoring code: 04107)
• Engine controller checks primary (coil) side of glow plug relay (connector M16) with failure
code [#B0541] or [#B0543].
Related
• Engine controller checks engine coolant temperature sensor with failure code [#B0117] or
information [#B0118].
• If machine monitor does not light up when starting switch is turned to ON position, main
power supply system may be defective. Perform troubleshooting for “Engine does not start
(engine does not crank)” and “When starting switch is turned to ON position, machine
monitor displays nothing” in E mode.

No. Cause Procedure, measuring location, criteria and remarks

If slow-blow fuse TM14 is blown out, circuit probably has ground fault. In this case,
1 Defective slow-blow fuse perform troubleshooting for ground fault in wiring harness (contact to ground circuit)
first.
1. Turn the starting switch to OFF position.
2. Replace glow plug relay (connector M13) with starter relay (connector
Defective glow plug relay M16).
2 (internal open or short
3. Turn the starting switch to ON position.
circuit)
If automatic preheating starts when coolant temperature is below +5 °C, the original
glow plug relay is defective.
1. Turn the starting switch to OFF position.
2. Disconnect TM14, M13, and M23.
Between M23 (female) (1) and M13 (female) (4) Max. 1 Ω
Open circuit in wiring har-
ness Between M13 (female) (1) and TM14 Max. 1 Ω
3
(Wire breakage or defec- Between TM13 and alternator B terminal (TM2) Max. 1 Ω
tive contact of connector) Resistance Between alternator B terminal (TM2) and starting mo-
Max. 1 Ω
tor B terminal (TM16)
Between starting motor B terminal (TM16) and battery
Max. 1 Ω
(+) terminal
1. Turn the starting switch to OFF position.
4 Defective glow plug 2. Disconnect connector M23.
Continuity Between M23 (male) (1) and ground Continuity
If slow-blow fuse is not blown out, this check is not required.
1. Turn the starting switch to OFF position.
Ground fault in wiring
harness 2. Disconnect TM14 and M23.
5
(Contact with ground cir- Between ground and TM14 or M13 (female) (1) Min. 1 MΩ
cuit)
Resistance Between ground and M13 (female) (4) or M23 (female)
Min. 1 MΩ
(1)

40-216 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK

CIRCUIT DIAGRAM (ENGINE PREHEATING SYSTEM)

PC45MR-5, PC55MR-5 40-217

E-4 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MA-
CHINE MONITOR DISPLAYS NOTHING 40 TROUBLESHOOTING

E-4 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE

MONITOR DISPLAYS NOTHING
Failure When starting switch is turned to ON position, machine monitor displays nothing.
• When starting switch is turned to ON position, machine monitor displays KOMATSU logo,
password input screen (if set), working mode and travel speed check screen, and stand-
Related ard screen in order.
information • Battery voltage may drop sharply when engine is started, depending on ambient tempera-
ture and battery condition. In this case, machine monitor display may disappear for a
while. This phenomenon is not abnormal.

No. Cause Procedure, measuring location, criteria and remarks

Omission of turning bat- Turn starting switch to OFF position, and check that battery disconnect switch is
1 tery disconnect switch turned ON.
ON
Check battery voltage and specific gravity of battery electrolyte.

Insufficient battery ca- Battery voltage (per 1 cell) Min. 12 V

2
pacity Battery voltage (2cells in-line) Min. 24 V
Gravity of battery Min. 1.26
If fusible link M05 or M09 is burnt out, circuit probably has ground fault. (See
3 Defective fusible link
ground fault (contact to ground circuit) of wiring harness.)
If fuse No.10 or No.13 in fuse box FB1 is blown out, circuit probably has ground
4 Defective fuse
fault. (See ground fault (contact to ground circuit) of wiring harness.)
1. Turn the starting switch to OFF position.
2. Disconnect the battery ground, or turn the battery disconnect switch to
OFF position.
3. Disconnect connector F15, and connect T-adapter.
Defective wiring harness, 4. Connect the battery ground, or turn the battery disconnect switch to ON
5 starting switch, or ma- position.
chine monitor 5. Turn the starting switch to ON position (connect ACC).
Between F15 (1) and (2) 10 to 15 V
Voltage Between F15 (6) and (7) 10 to 15 V
Between F15 (3) and (7) 10 to 15 V
1. Turn starting switch to OFF position.
2. Turn battery disconnect switch to OFF position.
Defective starting switch Turn starting switch to
6 Min. 1 MΩ
(internal open circuit) OFF position.
Resistance Between TF1 and TF3
Turn starting switch to
Max. 1 Ω
HEAT position.

40-218 PC45MR-5, PC55MR-5

E-4 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MA-
40 TROUBLESHOOTING CHINE MONITOR DISPLAYS NOTHING

No. Cause Procedure, measuring location, criteria and remarks

If no failure is found by check on cause 5, this check is not required.
1. Turn the starting switch to OFF position.
2. Disconnect the battery ground, or turn the battery disconnect switch to
OFF position.
3. Disconnect fusible links M05 and M09, fuses FB1 (10) and (13), and con-
nector F15.
4. Connect T-adapter to connectors M05 (male), M09 (male), and F15 (fe-
male).
Open circuit in wiring har- Between battery (-) terminal and ground Max. 1 Ω
7 ness
Between battery (+) terminal and M09 (male) (2) Max. 1 Ω
(Internal open circuit)
Between M09 (male) (1) and FB1 (11A) Max. 1 Ω
Between FB1 (13) and each of F15 (female) (1) and
Max. 1 Ω
Resistance (6)
Between battery (+) terminal and M05 (male) (2) Max. 1 Ω
Between M05 (male) (1) and TF1 Max. 1 Ω
Between TF3 and FB1 (1A) Max. 1 Ω
Between FB1 (10) and F15 (female) (3) Max. 1 Ω
If no failure is found by checks on causes 3, 4, and 5, this check is not required.
1. Turn the starting switch to OFF position.
2. Disconnect the battery ground, or turn the battery disconnect switch to
OFF position.
3. Disconnect fusible links M05 and M09, fuses FB1 (10) and (13), and con-
nectors F15 and CP01.
4. Connect T-adapter to connectors M05 (male), M09 (male), and F15 (fe-
Ground fault in wiring male).
harness
8 Between ground and battery (+) terminal or M09
(Contact with ground cir- Min. 1 MΩ
(male) (2)
cuit)
Between ground and M09 (male) (1) or FB1 (11A) Min. 1 MΩ
Between ground and each of FB1 (13), F15 (female)
Resistance Min. 1 MΩ
(1) and (6)
Between ground and M05 (male) (1) or TF1 Min. 1 MΩ
Between ground and TF3 or FB1 (1A) Min. 1 MΩ
Between ground and FB1 (10) or F15 (female) (3) Min. 1 MΩ
Defective machine moni- If no failure is found by above checks, machine monitor is defective. (Since this is
9
tor an internal defect, troubleshooting cannot be performed.)

PC45MR-5, PC55MR-5 40-219

E-4 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MA-
CHINE MONITOR DISPLAYS NOTHING 40 TROUBLESHOOTING

Circuit diagram related to machine monitor power supply

40-220 PC45MR-5, PC55MR-5

E-5 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN
40 TROUBLESHOOTING WHITE WHILE ENGINE IS RUNNING

E-5 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE

WHILE ENGINE IS RUNNING
Failure Engine coolant temperature monitor lights up in white while engine is running.
• Signal of engine coolant temperature sensor is input to engine controller, and then it is
transmitted to machine monitor via machine controller through CAN communication sys-
Related
tem.
information
• Engine coolant temperature can be checked with monitoring function.
(Code: 04107)

No. Cause Procedure, measuring location, criteria and remarks

Insufficient warm-up op- If monitor is lit in white, engine coolant temperature may be low (approximately
eration of machine 59°C and below). Warm up engine.
1 • Lights up in white: Engine coolant temperature is low.
(When system works
properly) • Lights up in blue: Coolant temperature is proper.
If no failure is found by preceding checks, engine coolant temperature gauge sys-
tem may be defective. Perform following troubleshooting.
Defective engine coolant • E-mode “ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES
2 temperature gauge sys- NOT MOVE FROM MINIMUM OR MAXIMUM”
tem • E-mode “DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIF-
FERS FROM ACTUAL COOLANT TEMPERATURE”(indicates neither full
nor empty)

PC45MR-5, PC55MR-5 40-221

E-6 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE
IS RUNNING 40 TROUBLESHOOTING

E-6 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS

RUNNING
Failure Charge level monitor lights up in red while engine is running.
Related
Generated signal condition of alternator can be checked with monitoring function (Code: 04300)
information

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Start the engine
1 Defective alternator
Between M10 (1) and Immediately after starting 13.5 to
Voltage
ground the engine 14.5 V
Ground fault in wiring Perform troubleshooting for failure code [#B1568].
2 harness (contact with
ground circuit)

Circuit diagram related to battery charge

40-222 PC45MR-5, PC55MR-5

E-7 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS
40 TROUBLESHOOTING RUNNING

E-7 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUN-

NING
Failure Fuel level monitor lights up in red while engine is running.
Related • Signal voltage of fuel sensor can be checked with monitoring function.
information (Code: 04200)

No. Cause Procedure, measuring location, criteria and remarks

Fuel level reduction Because fuel level may be lowered, check and refill with fuel if level is lowered.
1 (When system works
properly)
If no failure is found by preceding checks, fuel gauge system may be defective.
Perform following troubleshooting:
Defective fuel gauge sys- • E-mode “FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM
2 OR MAXIMUM”
tem
• E-mode “DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL
LEVEL” (indicates neither full nor empty).

PC45MR-5, PC55MR-5 40-223

E-8 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN
RED WHILE ENGINE IS RUNNING 40 TROUBLESHOOTING

E-8 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED

WHILE ENGINE IS RUNNING
Failure Engine coolant temperature monitor lights up in red while engine is running.
• Signal voltage of engine coolant temperature sensor is input to engine controller, and then
Related it is transmitted to machine monitor via machine controller through CAN communication
information system.
• Engine coolant temperature can be checked with monitoring function. (Code: 04107)

No. Cause Procedure, measuring location, criteria and remarks

If monitor is lit in red, coolant temperature may be high (above approximately
107 °C). Cool down coolant. (Run engine at low idle speed.)
Overheat of engine cool- • Lights up in red: Coolant temperature is high (overheating).
1 ant (when system works
• Lights up in blue: Coolant temperature is proper.
properly)
• Perform troubleshooting S-mode “COOLANT TEMPERATURE RISES
TOO HIGH (OVERHEATING).”
If no failure is found by preceding checks, engine coolant temperature gauge sys-
tem may be defective. Perform following troubleshooting.
Defective engine coolant • E-mode “ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES
2 temperature gauge sys- NOT MOVE FROM MINIMUM OR MAXIMUM”
tem • E-mode “DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIF-
FERS FROM ACTUAL COOLANT TEMPERATURE”(indicates neither full
nor empty)

40-224 PC45MR-5, PC55MR-5

E-9 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE
40 TROUBLESHOOTING ENGINE IS RUNNING

E-9 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE

IS RUNNING
Failure Engine oil pressure monitor lights up in red while engine is running
• Engine oil pressure switch signals are input to engine controller.
Related • If engine oil pressure switch is turned on while engine is running, engine controller sends
information the failure code [#B1198] to machine monitor through machine controller by CAN commu-
nication.

No. Cause Procedure, measuring location, criteria and remarks

Low engine oil pressure Since engine oil pressure low is sensed, check engine oil pressure.
1 (when system works • Perform troubleshooting S-mode “OIL PRESSURE DROPS.”
properly)
If failure code still displays after above checks on cause 1, engine oil pressure
Defective engine oil pres-
2 switch system may be defective. Perform troubleshooting for failure codes
sure system
[#B1198].
Defective machine moni- If no failure can be found in causes 1 and 2, machine monitor is defective. (Be-
3
tor cause this is an internal defect, troubleshooting cannot be performed.)

PC45MR-5, PC55MR-5 40-225

E-10 FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR
MAXIMUM 40 TROUBLESHOOTING

E-10 FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXI-
MUM
Failure Fuel gauge display does not move from minimum or maximum.
Related • Signal voltage of fuel sensor can be checked with monitoring function.
information (Code: 04200)

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
Defective fuel level sen- 2. Disconnect connector M06, and connect T-adapter to male side.
sor
1 Fuel level FULL 0 to 2 Ω
(Internal open or short Between M06 (male) (2)
circuit) Resistance 140 to
and (3) Fuel level EMPTY
160 Ω
1. Turn the starting switch to OFF position.
2. Disconnect connector CP01, and connect T-adapter to female side.
Open or short circuit in
2 Fuel level FULL 0 to 2 Ω
wiring harness
Between CP01 (female)
Resistance 140 to
(69) and (51) Fuel level EMPTY
160 Ω

REMARK
If no failure is found by check on cause 2, this check is not required.
Open circuit in wiring har- 1.
Turn the starting switch to OFF position.
ness
3 2. Disconnect connectors CP01 and M06, and connect T-adapter to each fe-
(Wire breakage or defec-
male side.
tive contact of connector)
Between CP01 (female) (69) and M06 (female) (2) Max. 1 Ω
Resistance
Between CP01 (female) (51) and M06 (female) (3) Max. 1 Ω

REMARK
If no failure is found by check on cause 2, this check is not required.
Ground fault in wiring
1. Turn the starting switch to OFF position.
harness
4 2.
(Contact with ground cir- Disconnect connectors CP01 and M06, and connect T-adapter to either fe-
cuit) male side.
Between ground and CP01 (female) (69) or M06 (fe-
Resistance Min. 1 MΩ
male) (2)
1. Turn the starting switch to OFF position.
2. Disconnect connector M06.
3. Insert T-adapter into connector CP01, or connect T-adapter to female side
of M06.
4. Turn starting switch to ON position.
Hot short circuit in wiring
5 REMARK
harness
• If voltage is 0 V, wiring harness has open circuit, ground fault, or short cir-
cuit, and if voltage is 12 V, wiring harness has hot short circuit.
• Voltage of approximately 5 V is applied to fuel level sensor signal circuits
through resistor in machine controller.
Voltage Between ground and CP01 (69) or M06 (female) (2) Approx. 5 V
Defective machine con- If no failure is found by preceding checks, work equipment controller is defective.
6
troller (Since this is an internal defect, troubleshooting cannot be performed.)

40-226 PC45MR-5, PC55MR-5

E-10 FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR
40 TROUBLESHOOTING MAXIMUM

Circuit diagram related to fuel level sensor

PC45MR-5, PC55MR-5 40-227

E-11 DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL LEV-
EL 40 TROUBLESHOOTING

E-11 DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL LEVEL

Failure Display of fuel gauge differs from actual fuel level.
Related • Signal voltage of fuel sensor can be checked with monitoring function
information (Code: 04200)

No. Cause Procedure, measuring location, criteria and remarks

Defective fuel level sen- Perform the check on cause 1 of “The pointer of fuel gauge does not move from
1
sor minimum or maximum”

40-228 PC45MR-5, PC55MR-5

E-12 ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES
40 TROUBLESHOOTING NOT MOVE FROM MINIMUM OR MAXIMUM

E-12 ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES NOT

MOVE FROM MINIMUM OR MAXIMUM
Failure Engine coolant temperature gauge indication does not move from minimum or maximum.
• Signal of engine coolant temperature sensor is input to engine controller, and then it is
transmitted to machine monitor via machine controller through CAN communication sys-
Related
tem.
information
• Engine coolant temperature can be checked with monitoring function.
(Code: 04107)

No. Cause Procedure, measuring location, criteria and remarks

Defective engine coolant Coolant temperature sensor system may be defective. Perform troubleshooting for
1 temperature sensor sys- failure codes [#B0117] and [#B0118].
tem
If failure code still displays after above checks on Cause 1, machine monitor may
Defective machine moni- be defective.
2
tor (In case of an internal defect, troubleshooting is impossible as an assembly. Re-
place whole assembly.)

PC45MR-5, PC55MR-5 40-229

E-13 DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIF-
FERS FROM ACTUAL COOLANT TEMPERATURE 40 TROUBLESHOOTING

E-13 DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIFFERS

FROM ACTUAL COOLANT TEMPERATURE
Failure Engine coolant temperature gauge does not indicate correct temperature
• Signal of engine coolant temperature sensor is input to engine controller, and then it is
transmitted to machine monitor via machine controller through CAN communication sys-
Related
tem.
information
• Engine coolant temperature can be checked with monitoring function.
(Code: 04107)

No. Cause Procedure, measuring location, criteria and remarks

Defective engine coolant Coolant temperature sensor system may be defective. Perform troubleshooting for
1 temperature sensor sys- failure codes [#B0117] and [#B0118].
tem

40-230 PC45MR-5, PC55MR-5

E-14 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DIS-
40 TROUBLESHOOTING PLAYED

E-14 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DIS-

PLAYED
Failure • Some areas of machine monitor screen are not displayed.
Related
information

No. Cause Procedure, measuring location, criteria and remarks

Perform troubleshooting when starting switch is in ON position.
Defective machine moni-
tor When all the lights of liquid crystal display panel is on (entirely white) by the follow-
1 ing switch operation, machine monitor is normal.
(Liquid crystal display
panel part) • Switch operation: While pressing [F8], press [F6] and then release [F6] on-
ly.
If failure code still displays after above checks on Cause 1, machine monitor may
Defective machine moni- be defective.
2
tor (In case of an internal defect, troubleshooting is impossible as an assembly. Re-
place whole assembly.)

PC45MR-5, PC55MR-5 40-231

E-15 FUNCTION SWITCH DOES NOT OPERATE 40 TROUBLESHOOTING

E-15 FUNCTION SWITCH DOES NOT OPERATE

Failure Function switch does not work.
Related • Signal state of function switch can be checked with monitoring function.
information (Code: 04507, 04508)

No. Cause Procedure, measuring location, criteria and remarks

Defective machine moni- Machine monitor may be defective. (Because this is an internal defect, trouble-
1
tor shooting cannot be performed.)

40-232 PC45MR-5, PC55MR-5

E-16 AUTO-DECELERATOR IS NOT OPERATED OR CANCELED
40 TROUBLESHOOTING WITH LEVER

E-16 AUTO-DECELERATOR IS NOT OPERATED OR CANCELED WITH LEV-

ER
Failure Auto-deceleration function does not operate or is not canceled while lever is operated.
• Since set engine speed for auto-deceleration is 1000 rpm, auto-deceleration is not actuat-
Related
ed or canceled if engine speed set with fuel control dial is below this speed.
information
• Pressure switch signal can be checked with monitoring function.(Code:01900)

No. Cause Procedure, measuring location, criteria and remarks

1. Start the engine and perform troubleshooting (with monitoring function).
2. If display of monitoring is incorrect, perform troubleshooting for “MONI-
TORING FUNCTION DOES NOT INDICATE *** CORRECTLY” in E mode.
Travel (when lever is operated) ON
Travel (when lever is in NEUTRAL) OFF
Defective PPC oil pres-
1 Swing or arm IN (when lever is operated) ON
sure signal
Monitoring Swing or arm IN (when lever is in NEUTRAL) OFF
display
Work equipment (when any lever of boom, arm, buck-
ON
et, blade, boom swing, and service is operated)
Work equipment (when any lever of boom, arm, buck-
OFF
et, blade, boom swing, and service is in NEUTRAL)
Defective machine moni- If no failure is found by above checks, machine monitor is defective. (Since this is
2
tor an internal defect, troubleshooting cannot be performed.)
Defective machine con- If no failure is found by preceding checks, work equipment controller is defective.
3
troller (Since this is an internal defect, troubleshooting cannot be performed.)
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
4
ler an internal defect, troubleshooting cannot be performed.)

PC45MR-5, PC55MR-5 40-233

E-17 WHEN WORKING MODE IS CHANGED, SETTING OF ENGINE
AND HYDRAULIC PUMP IS NOT CHANGED 40 TROUBLESHOOTING

E-17 WHEN WORKING MODE IS CHANGED, SETTING OF ENGINE AND

HYDRAULIC PUMP IS NOT CHANGED
Failure Setting of engine and hydraulic pump is not changed when working mode is changed.
Related
information

No. Cause Procedure, measuring location, criteria and remarks

Defective machine moni- Machine monitor may be defective. (Because this is an internal defect, trouble-
1
tor shooting cannot be performed.)
Defective machine con- If no failure is found by preceding checks, work equipment controller is defective.
2
troller (Since this is an internal defect, troubleshooting cannot be performed.)

40-234 PC45MR-5, PC55MR-5

E-18 WHEN TRAVEL SPEED SELECTION IS CHANGED, ACTUAL
40 TROUBLESHOOTING TRAVEL SPEED DOES NOT CHANGE

E-18 WHEN TRAVEL SPEED SELECTION IS CHANGED, ACTUAL TRAVEL

SPEED DOES NOT CHANGE
Failure Travel speed does not change after the travel speed is changed.
• As T-adapter for machine controller connector is “socket-type box”, operating voltage can-
Related infor- not be measured at machine controller connector.
mation • If failure code [DW43KA], [DW43KB], or [DW43KY] is displayed, perform troubleshooting
for these failure codes first.

No. Cause Procedure, measuring location, criteria and remarks

If fuse No.5 in fuse box FB1 is blown out, circuit probably has ground fault. (See
1 Defective fuse
ground fault (contact to ground circuit) of wiring harness.)
1. Turn the starting switch to OFF position.
2. Disconnect connector F38, and connect T-adapter to male side.
REMARK
Defective selector switch
Switch ON: Push
for 2nd travel speed (in-
2 Switch OFF: Release
ternal open circuit or
short circuit) Turn the starting switch to
Min. 1 MΩ
Between F38 (male) (1) OFF position.
Resistance
and (2) Turn the starting switch to
Max. 1 Ω
ON position.
1. Turn the starting switch to OFF position.
Open circuit in wiring har- 2. Disconnect connectors F38 and CP01, and connect T-adapter to each fe-
ness male side.
3
(Wire breakage or defec-
Between FB1 (5) and F38 (female) (1) Max. 1 Ω
tive contact of connector) Resistance
Between F38 (female) (2) and CP01 (female) (61) Max. 1 Ω
If fuse is not blown out, this check is not required.
1. Turn the starting switch to OFF position.
Ground fault in wiring 2. Remove fuse FB1 (5).
harness
4 3. Disconnect connectors F38 and CP02, and connect T-adapter to each fe-
(Contact with ground cir- male side.
cuit)
Between ground and FB1 (5) or F38 (female) (1) Min. 1 MΩ
Resistance
Between F38 (female) (2) and ground Min. 1 MΩ
Defective machine con- If no failure is found by preceding checks, work equipment controller is defective.
5
troller (Since this is an internal defect, troubleshooting cannot be performed.)

PC45MR-5, PC55MR-5 40-235

E-18 WHEN TRAVEL SPEED SELECTION IS CHANGED, ACTUAL
TRAVEL SPEED DOES NOT CHANGE 40 TROUBLESHOOTING

Circuit diagram related to travel speed solenoid

40-236 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING E-19 ALARM BUZZER DOES NOT SOUND

E-19 ALARM BUZZER DOES NOT SOUND

Failure Alarm buzzer does not sound.
• When turning the starting switch from OFF to ON position, buzzer sound by self check is
not heard (for 2 seconds).
Related
• When travel speed increasing switch and function switch are pressed while starting switch
information is in ON position, no switching sound is heard (short sound).
• Check that fuse FB1 (5) is not blown out before performing troubleshooting.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Insert T-adapter in connector F28, and connect T-adapter box to it.
3. Turn the starting switch to ON position.
1 Defective alarm buzzer 4. Connect No.1 of T-adapter box to the ground.
Buzzer
It sounds only when connected,
sound
Voltage Between F28 (2) and ground 10 to 15 V
1. Turn the starting switch to OFF position.
2. Disconnect connectors F15 and F28, and connect T-adapter to each fe-
Open circuit in wiring har-
2 ness (wire breakage or male side.
defective contact) Between F15 (female) (5) and F28 (female) (1) Max. 1 Ω
Resistance
Between FB1 (5) and F28 (female) (2) Max. 1 Ω
1. Turn the starting switch to OFF position.
2. Disconnect connector F15, and connect T-adapter and T-adapter box to
female side.
Defective machine moni- 3.
3 Turn the starting switch to ON position.
tor
4. Connect No.5 of T-adapter box to the ground.
Buzzer
It sounds only when connected,
sound

Circuit diagram related to alarm buzzer

PC45MR-5, PC55MR-5 40-237

E-20 ALARM BUZZER CANNOT BE CANCELED 40 TROUBLESHOOTING

E-20 ALARM BUZZER CANNOT BE CANCELED

Failure Alarm buzzer does not stop sounding.
Related
Check that fuse FB1 (5) is not blown out before performing troubleshooting.
information

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
Defective machine moni- 2. Disconnect connector F15.
1
tor
Buzzer It stops
Turn the starting switch to ON position.
sound sounding.
1. Turn the starting switch to OFF position.
Ground fault in wiring 2. Disconnect connectors F15 and F28, and connect T-adapter to either fe-
2 harness (contact with male side.
ground circuit)
Between ground and F15 (female) (5) or F28 (female)
Resistance Min. 1 MΩ
(1)

Circuit diagram related to alarm buzzer

40-238 PC45MR-5, PC55MR-5

E-21 SERVICE METER IS NOT DISPLAYED, WHILE STARTING
40 TROUBLESHOOTING SWITCH IS IN OFF POSITION

E-21 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS

IN OFF POSITION
Failure Service meter is not displayed while starting switch is in OFF position.

Related • The following switch operation with the starting switch set to OFF position displays a serv-
ice meter in the middle of the screen.
information Operation of switches: [F2]+[F3] (pressed simultaneously)

No. Cause Procedure, measuring location, criteria and remarks

When starting switch is turned to ON position and machine monitor displays noth-
ing, backup power supply system may be defective and perform the following trou-
Defective backup power
1 bleshooting:
supply system
• E-mode “WHEN STARTING SWITCH IS TURNED TO ON POSITION,
MACHINE MONITOR DISPLAYS NOTHING”
If failure code still displays after above checks on Cause 1, machine monitor may
Defective machine moni- be defective.
2
tor (In case of an internal defect, troubleshooting is impossible as an assembly. Re-
place whole assembly.)

PC45MR-5, PC55MR-5 40-239

E-22 SERVICE MODE CANNOT BE SELECTED 40 TROUBLESHOOTING

E-22 SERVICE MODE CANNOT BE SELECTED

Failure Service mode cannot be selected.
Related
See “TESTING AND ADJUSTING”, “SERVICE MODE”
information

No. Cause Procedure, measuring location, criteria and remarks

Defective machine moni- Machine monitor may be defective. (Because this is an internal defect, trouble-
1
tor shooting cannot be performed.)

40-240 PC45MR-5, PC55MR-5

E-23 ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHA-
40 TROUBLESHOOTING NISM DO NOT MOVE

E-23 ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHANISM DO

NOT MOVE
Failure None of work equipment, swing or travel works.
• As for PPC lock lever relay system, troubleshooting is performed by failure codes [DKUL-
Related
KA] and [DKULKB].
information
• As for PPC lock switch system, troubleshooting is performed by failure code [DDNRKA].

No. Cause Procedure, measuring location, criteria and remarks

If fuse No.3 in fuse box FB1 is blown out, circuit probably has ground fault. (See
1 Defective fuse
ground fault (contact to ground circuit) of wiring harness.)
Defective PPC lock Perform troubleshooting for failure code [DDNRKA].
2
switch (internal open)
Defective PPC lock relay Perform troubleshooting for failure codes [DKULKA] and [DKULKB].
3 (internal open or short
circuit)
1. Turn the starting switch to OFF position.
Defective PPC lock sole-
noid 2. Disconnect connector M18, and connect T-adapter to male side.
4
(Internal open, short cir- Between M18 (male) (1) and (2) 8 to 15 Ω
cuit, or ground fault) Resistance
Between M18 (male) (1) and ground Min. 1 MΩ
1. Turn starting switch to OFF position.
2. Disconnect connector D01 and connect T-adapter to male side.
Defective diode array REMARK
5 D01 Measure it with diode range of multimeter.
(Internal ground fault)
Between D01 (male) (5) (+) and (1) (-) Continuity
Continuity No continui-
Between D01 (male) (1) (+) and (5) (-)
ty
1. Turn the starting switch to OFF position.
2. Disconnect connector R02, and connect T-adapter to female side.
3. Turn the starting switch to ON position.
Open or short circuit in 4. Set the lock lever to FREE position.
6
wiring harness
Between R02 (female) (5) and ground
Resistance 8 to 15 Ω
(Resistance of PPC lock solenoid)
Voltage Between R02 (female) (3) and ground Min. 10 V
If no failure is found by check on cause 6, this check is not required.
1. Turn the starting switch to OFF position.
2. Remove fuse No.3.
3. Disconnect connectors F09, M18, and R02, and connect T-adapter to each
Open circuit in wiring har- female side.
7
ness Between M18 (female) (2) and ground Max. 1 Ω
Between M18 (female) (1) and R02 (female) (5) Max. 1 Ω
Resistance
Between R02 (female) (3) and F09 (male) (B) Max. 1 Ω
Between FB1 (3) and F09 (male) (A) Max. 1 Ω

PC45MR-5, PC55MR-5 40-241

E-23 ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHA-
NISM DO NOT MOVE 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

If no failure is found by check on cause 1, this check is not required.
1. Turn the starting switch to OFF position.
2. Remove fuse No.3.
Ground fault in wiring 3. Disconnect connectors F09, D01, and M18, and then connect T-adapter to
harness male side of F09 or female side of M18.
8
(Contact with ground cir- Between ground and M18 (female) (1) or R02 (female)
Min. 1 MΩ
cuit) (5)
Resistance Between ground and R02 (female) (3) or F09 (male)
Min. 1 MΩ
(B)
Between F09 (male) (A) and ground Min. 1 MΩ

Circuit diagram related to PPC lock switch

40-242 PC45MR-5, PC55MR-5

E-24 ALL OF WORK EQUIPMENT, SWING, AND TRAVEL MECHA-
40 TROUBLESHOOTING NISM DO NOT LOCK

E-24 ALL OF WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO

NOT LOCK
Failure Any of work equipment, swing, and travel cannot be locked.
• As for PPC lock lever relay system, troubleshooting is performed by failure code [DKUL-
Related
KY].
information
• As for PPC lock switch system, troubleshooting is performed by failure code [DDNRKY].

No. Cause Procedure, measuring location, criteria and remarks

Defective PPC lock Perform troubleshooting for failure code [DDNRKY].
1 switch (internal short cir-
cuit)
Defective PPC lock lever Perform troubleshooting for failure code [DKULKY].
2 relay (internal short cir-
cuit)
1. Turn the starting switch to OFF position.
Hot short circuit in wiring 2. Disconnect connector M18, and connect T-adapter to female side.
harness
3 3. Turn the starting switch to ON position.
(Contact with 12 V cir-
4. Turn the lock lever to LOCK position.
cuit)
Voltage Between M18 (female) (2) and (1) Max.1 V

PC45MR-5, PC55MR-5 40-243

E-24 ALL OF WORK EQUIPMENT, SWING, AND TRAVEL MECHA-
NISM DO NOT LOCK 40 TROUBLESHOOTING

Circuit diagram related to PPC lock switch

40-244 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING E-25 ALARM DOES NOT SOUND DURING TRAVEL

E-25 ALARM DOES NOT SOUND DURING TRAVEL

Failure Alarm does not sound during travel.
Related
Work in pairs.
information

No. Cause Procedure, measuring location, criteria and remarks

Perform troubleshooting when starting switch is at OFF position and engine is run-
ning.
If monitoring data is not displayed normally, perform troubleshooting for ““Travel” is
1 Defective travel signal not displayed correctly with monitoring function” in E mode.
Travel signal ON
Monitoring
01900: Pressure switch 1 Travel signal (when lever
display OFF
is in NEUTRAL)
1. Turn the starting switch to OFF position.
2. Disconnect connector M08, and connect T-adapter to female side.
3. Start the engine, and operate the travel lever.
k
Defective travel alarm
2 When driving machine, do not measure under the machine.
(Internal defect)
REMARK
If the voltage is normal but the alarm does not sound, travel alarm is defective.
Voltage Between M08 (female) (1) and (2) 10 to 15 V
1. Turn the starting switch to OFF position.
Open circuit in wiring har- 2. Disconnect connectors M08 and CP02, and connect T-adapters to each
ness female side.
3
(Wire breakage or defec-
Between CP02 (female) (86) and M08(female) (1) Max. 1 Ω
tive contact of connector) Resistance
Between M08 (female) (2) and ground Max. 1 Ω
1. Turn the starting switch to OFF position.
Ground fault in wiring
2. Disconnect connectors CP02 and M08, and connect T-adapter to either fe-
harness
4 male side.
(Contact with ground cir-
cuit) Between CP02 (female) (86) and ground, or M08 (fe-
Resistance Min. 1 MΩ
male) (1) and ground

PC45MR-5, PC55MR-5 40-245

E-25 ALARM DOES NOT SOUND DURING TRAVEL 40 TROUBLESHOOTING

Circuit diagram related to travel alarm

40-246 PC45MR-5, PC55MR-5

E-26 ALARM DOES NOT STOP SOUNDING WHILE MACHINE IS
40 TROUBLESHOOTING STOPPED

E-26 ALARM DOES NOT STOP SOUNDING WHILE MACHINE IS STOPPED

Failure Alarm does not stop sounding while machine is stopped.
Related
information

No. Cause Procedure, measuring location, criteria and remarks

Defective travel PPC oil Perform troubleshooting for failure code [DHS5MA].
pressure sensor system
1
(internal open or short
circuit)
1. Turn the starting switch to OFF position.
Hot short circuit in wiring
harness 2. Disconnect connector M08, and connect T-adapter to female side.
2
(Contact with 12 V cir- 3. Turn the starting switch to ON position.
cuit)
Voltage Between M08 (female) (1) and ground Max. 1 V

Circuit diagram related to travel alarm

PC45MR-5, PC55MR-5 40-247

E-27 HORN DOES NOT SOUND 40 TROUBLESHOOTING

E-27 HORN DOES NOT SOUND

Failure Horn does not sound.
Related
information

No. Cause Procedure, measuring location, criteria and remarks

If fuse FB1-5 is blown out, the circuit probably has ground fault. In this case, per-
1 Defective fuse
form check on cause 7 first.
1. Turn starting switch to OFF position.
Defective horn relay 2. Replace horn relay (connector: R03) with another relay.
2 (Internal open or short 3. Turn starting switch to ON position.
circuit) 4. Press R.H. knob switch.
If horn sounds, original horn relay is defective.
1. Turn starting switch to OFF position.
Defective horn switch 2. Disconnect connector F13 and connect T-adapter to male side.
3 (Internal open or short
Between F13 (male) (1) Switch: OFF Min. 1 MΩ
circuit) Resistance
and (2) Switch: ON Max. 1 Ω
1. Turn the starting switch to OFF position.
Defective horn (internal 2.
4 Disconnect connector M01 and connect T-adapters to each male side.
open or short circuit)
Continuity Between M01 (male) (1) and (2) Continuity
1. Turn the starting switch to OFF position.
2. Disconnect connector R03, and connect T-adapter to female side.
3. Turn the starting switch to ON position.
5 Defective wiring harness
4. Press R.H. knob switch.
Between R03 (female) (1) and (2) 10 to 15 V
Voltage
Between R03 (female) (3) and (2) 10 to 15 V
1. Turn the starting switch to OFF position.
2. Disconnect connector R03, and connect T-adapter to female side.
Between R03 (female) (2) and ground Continuity
Continuity
Between R03 (female) (5) and ground Continuity
If no failure is found by check on cause 5 or preceding check, this check is not re-
quired.
1. Turn the starting switch to OFF position.
Open circuit in wiring har- 2. Remove fuse FB1-5.
6 ness (wire breakage or 3. Disconnect connectors F13, R03, and M01, and connect T-adapter to each
defective contact)
connector.
Between FB1 (5) and F13 (female) (2) Max. 1 Ω
Between F13 (female) (1) and R03 (female) (1) Max. 1 Ω
Between R03 (female) (2) and ground Max. 1 Ω
Resistance
Between FB1 (5) and R03 (female) (3) Max. 1 Ω
Between R03 (female) (5) and M01 (female) (1) Max. 1 Ω
Between M01 (female) (2) and ground Max. 1 Ω

40-248 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING E-27 HORN DOES NOT SOUND

No. Cause Procedure, measuring location, criteria and remarks

If fuse is not blown out, this check is not required.
1. Turn the starting switch to OFF position.
2. Remove fuse FB1-5.
3. Disconnect connectors F13, R03, and M01, and connect T-adapter to each
Ground fault in wiring female side.
7 harness (contact with Between ground and F13 (female) (2) or R03 (female)
ground circuit) Min. 1 MΩ
(3)
Between ground and F13 (female) (1) or R03 (female)
Resistance Min. 1 MΩ
(1)
Between ground and R03 (female) (5) or M01 (female)
Min. 1 MΩ
(1)
Defective horn (internal If no failure is found by above checks, horn may be defective.
8
defect)

Circuit diagram related to horn

PC45MR-5, PC55MR-5 40-249

E-28 HORN DOES NOT SOUND (FOR PROPORTIONAL LEVER SPEC) 40 TROUBLESHOOTING

E-28 HORN DOES NOT SOUND (FOR PROPORTIONAL LEVER SPEC)

Failure Horn does not sound (for proportional lever spec).
Related
information

No. Cause Procedure, measuring location, criteria and remarks

If fuse FB1-5 is blown out, the circuit probably has ground fault. In this case, per-
1 Defective fuse
form check on cause 7 first.
1. Turn starting switch to OFF position.
Defective horn relay 2. Replace horn relay (connector: R03) with another relay.
2 (Internal open or short 3. Turn starting switch to ON position.
circuit) 4. Press R.H. knob switch.
If horn sounds, original horn relay is defective.
1. Turn starting switch to OFF position.
Defective horn switch 2. Disconnect connector F26 and connect T-adapter to male side.
3 (Internal open or short
Between F26 (male) (7) Switch: OFF Min. 1 MΩ
circuit) Resistance
and (6) Switch: ON Max. 1 Ω
1. Turn the starting switch to OFF position.
Defective horn (internal 2.
4 Disconnect connector M01 and connect T-adapters to each male side.
open or short circuit)
Continuity Between M01 (male) (1) and (2) Continuity
1. Turn the starting switch to OFF position.
2. Disconnect connector R03, and connect T-adapter to female side.
3. Turn the starting switch to ON position.
5 Defective wiring harness
4. Press R.H. knob switch.
Between R03 (female) (1) and (2) 10 to 15 V
Voltage
Between R03 (female) (3) and (2) 10 to 15 V
1. Turn the starting switch to OFF position.
2. Disconnect connector R03, and connect T-adapter to female side.
Between R03 (female) (2) and ground Continuity
Continuity
Between R03 (female) (5) and ground Continuity
If no failure is found by check on cause 5 or preceding check, this check is not re-
quired.
1. Turn the starting switch to OFF position.
Open circuit in wiring har- 2. Remove fuse FB1-5.
6 ness (wire breakage or 3. Disconnect connectors F26, R03, and M01, and connect T-adapter to each
defective contact)
connector.
Between FB1 (5) and F26 (female) (6) Max. 1 Ω
Between F26 (female) (7) and R03 (female) (1) Max. 1 Ω
Between R03 (female) (2) and ground Max. 1 Ω
Resistance
Between FB1 (5) and R03 (female) (3) Max. 1 Ω
Between R03 (female) (5) and M01 (female) (1) Max. 1 Ω
Between M01 (female) (2) and ground Max. 1 Ω

40-250 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING E-28 HORN DOES NOT SOUND (FOR PROPORTIONAL LEVER SPEC)

No. Cause Procedure, measuring location, criteria and remarks

If fuse is not blown out, this check is not required.
1. Turn the starting switch to OFF position.
2. Remove fuse FB1-5.
3. Disconnect connectors F26, R03, and M01, and connect T-adapter to each
Ground fault in wiring
female side.
harness
7 Between ground and F26 (female) (6) or R03 (female)
(Contact with ground cir- Min. 1 MΩ
cuit) (3)
Between ground and F26 (female) (7) or R03 (female)
Resistance Min. 1 MΩ
(1)
Between ground and R03 (female) (5) or M01 (female)
Min. 1 MΩ
(1)
Defective horn (internal If no failure is found by above checks, horn may be defective.
8
defect)

Circuit diagram related to horn (for proportional lever spec)

PC45MR-5, PC55MR-5 40-251

E-29 HORN DOES NOT STOP SOUNDING 40 TROUBLESHOOTING

E-29 HORN DOES NOT STOP SOUNDING

Failure Horn does not stop sounding.
Related
information

No. Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connector F13 and connect T-adapter to male side.
1 Defective horn switch
Between F13 (male) (1) Switch: OFF Min. 1 MΩ
Resistance
and (2) Switch: ON Max. 1 Ω
1. Turn starting switch to OFF position.
Defective horn relay 2. Remove horn relay (connector R03).
2 (Internal open or short 3. Turn starting switch to ON position.
circuit)
If horn stops sounding, the original horn relay is defective.
1. Turn the starting switch to OFF position.
2. Disconnect connectors M01 and R03, and connect T-adapter to each fe-
Hot short circuit in wiring
harness male side.
3 3. Turn the starting switch to ON position.
(Contact with 12 V cir-
cuit) Between M01 (female) (2) and (1) Max. 1 V
Voltage
Between R03 (female) (1) and (2) Max. 1 V

40-252 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING E-29 HORN DOES NOT STOP SOUNDING

Circuit diagram related to horn

PC45MR-5, PC55MR-5 40-253

E-30 HORN DOES NOT STOP SOUNDING (FOR PROPORTIONAL
LEVER SPEC) 40 TROUBLESHOOTING

E-30 HORN DOES NOT STOP SOUNDING (FOR PROPORTIONAL LEVER

SPEC)
Failure Horn does not stop sounding (for proportional lever spec).
Related
information

No. Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Defective horn switch 2. Disconnect connector F26 and connect T-adapter to male side.
1 (Internal open or short
Between F26 (male) (7) Switch: OFF Min. 1 MΩ
circuit) Resistance
and (6) Switch: ON Max. 1 Ω
1. Turn starting switch to OFF position.
Defective horn relay 2. Remove horn relay (connector R03).
2 (Internal open or short 3. Turn starting switch to ON position.
circuit)
If horn stops sounding, the original horn relay is defective.
1. Turn the starting switch to OFF position.
2. Disconnect connectors F26, R03, and M01, and connect T-adapter to each
Hot short circuit in wiring
harness female side.
3 3. Turn the starting switch to ON position.
(Contact with 12 V cir-
cuit) Between R03 (female) (1) and (2) Max. 1 V
Voltage
Between M01 (female) (2) and (1) Max. 1 V

40-254 PC45MR-5, PC55MR-5

E-30 HORN DOES NOT STOP SOUNDING (FOR PROPORTIONAL
40 TROUBLESHOOTING LEVER SPEC)

Circuit diagram related to horn (for proportional lever spec)

PC45MR-5, PC55MR-5 40-255

E-31 WORKING LAMP OR TRAVEL LAMP DOES NOT LIGHT UP
(CANOPY SPEC) 40 TROUBLESHOOTING

E-31 WORKING LAMP OR TRAVEL LAMP DOES NOT LIGHT UP (CANOPY

SPEC)
Failure Working lamp or travel lamp does not light up (canopy spec).

Related If working lamp relay or working lamp switch or diode or common wiring harness of working lamp
and travel lamp is defective, neither working lamp nor travel lamp does not light up. (If either of them
information lights up, check the cause on these failures is not required.)

No. Cause Procedure, measuring location, criteria and remarks

Defective working lamp Since working lamp and travel lamp may be defective, check their bulbs for burned-
1
or travel lamp out.
If fuse No.1 and No.11 in fuse box FB1 are blown out, circuit probably has ground
2 Defective fuse fault, etc. Accordingly, perform troubleshooting for “Ground fault of wiring harness”
first.
1. Turn the starting switch to OFF position.
Defective working lamp 2. Replace working lamp relay R04 with another one.
relay 3.
3 Turn the starting switch to ON position.
(Internal open or short
circuit) 4. Turn on the working lamp switch.
If working lamp lights up, original working lamp relay is defective.
1. Turn the starting switch to OFF position.
2. Disconnect connector S02, and connect T-adapter to male side.
3. Turn the working lamp switch to ON/OFF position to perform troubleshoot-
ing. (ON is available for both directions.)
Defective working lamp
4 OFF Min. 1 MΩ
switch Between S02 (male) (5)
and (6) ON Max. 1 Ω
Resistance
Between S02 (male) (5) OFF Min. 1 MΩ
and (4) ON Max. 1 Ω
1. Turn the starting switch to OFF position.
2. Disconnect connector D01, and connect T-adapter to male side.
REMARK
Measure it with diode range of multimeter.
Defective diode
5 No continui-
(internal open or short Between D01 (male) (3) (+) and (7) (-)
ty
circuit)
Between D01 (male) (7) (+) and (3) (-) Continuity
Continuity
No continui-
Between D01 (male) (4) (+) and (8) (-)
ty
Between D01 (male) (8) (+) and (4) (-) Continuity

40-256 PC45MR-5, PC55MR-5

E-31 WORKING LAMP OR TRAVEL LAMP DOES NOT LIGHT UP
40 TROUBLESHOOTING (CANOPY SPEC)

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect connectors W02 and W03, and connect T-adapter to each fe-
male side.
3. Turn the starting switch to ON position.
4. Turn on the working lamp switch.
Between W02 (female) (A) and (B) 10 to 15 V
Voltage
Between W03 (female) (1) and (2) 10 to 15 V
If no failure is found by preceding checks, this check is not required.
1. Turn the starting switch to OFF position.
2. Disconnect connector W01, and connect T-adapter to female side.
3. Turn the starting switch to ON position.
4. Turn on the working lamp switch.
Open or short circuit in
6 Voltage Between W01 (female) (1) and (2) 10 to 15 V
wiring harness
If no failure is found by preceding checks, this check is not required.
1. Turn the starting switch to OFF position.
2. Disconnect connector R04, and connect T-adapter to female side.
3. Turn the starting switch to ON position.
4. Turn on the working lamp switch.
Between R04 (female) (1) and (2) 10 to 15 V
Voltage
Between R04 (female) (3) and (2) 10 to 15 V
If no failure is found by preceding checks, this check is not required.
1. Turn the starting switch to OFF position.
2. Disconnect connector S02, and connect T-adapter to female side.
3. Turn the starting switch to ON position.
Voltage Between S02 (female) (5) and (2) 10 to 15 V

PC45MR-5, PC55MR-5 40-257

E-31 WORKING LAMP OR TRAVEL LAMP DOES NOT LIGHT UP
(CANOPY SPEC) 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

If no failure is found by check on cause 6, this check is not required.
1. Turn the starting switch to OFF position.
2. Remove fuses FB1 (1) and FB1 (11).
3. Disconnect connectors S02, D01, R04, F03, W02, and W03, and connect
T-adapter to each female side.
Between W02 (female) (B) and ground Max. 1 Ω
Between W03 (female) (2) and ground Max. 1 Ω
Between W02 (female) (A) and R04 (female) (5) Max. 1 Ω
Open circuit in wiring har- Between W03 (female) (2) and R04 (female) (5) Max. 1 Ω
ness
7 Between R04 (female) (1) and D01 (female) (3) Max. 1 Ω
(wire breakage or defec-
tive contact of connector) Between R04 (female) (1) and D01 (female) (4) Max. 1 Ω

Resistance Between R04 (female) (2) and ground Max. 1 Ω

Between R04 (female) (3) and FB1 (11) Max. 1 Ω
Between D01 (female) (7) and each of S02 (female)
Max. 1 Ω
(1) and (6)
Between S02 (female) (2) and ground Max. 1 Ω
Between D01 (female) (8) and each of S02 (female)
Max. 1 Ω
(3) and (4)
Between S02 (female) (5) and FB1 (1) Max. 1 Ω
If no failure is found by check on cause 6, this check is not required.
1. Turn the starting switch to OFF position.
2. Remove fuses FB1 (1) and FB1 (11).
Ground fault in wiring 3. Disconnect connectors S02, D01, R04, W02, and W03, and connect T-
harness adapter to female side of S02 and R04.
8
(contact with ground cir- Between R04 (female) (1) and ground Min. 1 MΩ
cuit)
Between R04 (female) (3) and ground Min. 1 MΩ
Resistance
Between R04 (female) (5) and ground Min. 1 MΩ
Between S02 (female) (5) and ground Min. 1 MΩ

40-258 PC45MR-5, PC55MR-5

E-31 WORKING LAMP OR TRAVEL LAMP DOES NOT LIGHT UP
40 TROUBLESHOOTING (CANOPY SPEC)

Circuit diagram related to working lamp and travel lamp

PC45MR-5, PC55MR-5 40-259

E-32 NONE OF WORKING LAMP, TRAVEL LAMP, OR ADDITIONAL
LAMP DOES NOT LIGHT UP (CAB SPEC) 40 TROUBLESHOOTING

E-32 NONE OF WORKING LAMP, TRAVEL LAMP, OR ADDITIONAL LAMP

DOES NOT LIGHT UP (CAB SPEC)
Failure None of working lamp, travel lamp, or additional lamp lights up (cab spec).
If working lamp switch or diode or common wiring harness of working lamp, travel lamp, and addi-
tional lamp is defective, none of working lamp, travel lamp, or additional lamp lights up. (If any of
Related them lights up, check the cause on these failures is not required.)
information REMARK
Additional lamp is optional for cab spec.

No. Cause Procedure, measuring location, criteria and remarks

Defective working lamp, Since working lamp, travel lamp, or additional lamp may be defective, check their
1 travel lamp, or additional bulbs for burned-out.
lamp
If fuse No.1 and No.11 in fuse box FB1 are blown out, circuit probably has ground
2 Defective fuse fault, etc. Accordingly, perform troubleshooting for “Ground fault of wiring harness”
first.
1. Turn the starting switch to OFF position.
Defective working lamp 2. Replace working lamp relay R04 with another one.
relay 3.
3 Turn the starting switch to ON position.
(Internal open or short
circuit) 4. Turn on the working lamp switch.
If working lamp lights up, original working lamp relay is defective.
1. Turn the starting switch to OFF position.
2. Replace additional lamp relay R05 with another one.
Defective additional lamp
relay 3. Turn the starting switch to ON position.
4
(Internal open or short 4. Turn on the working lamp switch.
circuit)
If travel lamp and additional lamp light up, original additional lamp relay is defec-
tive.
1. Turn the starting switch to OFF position.
2. Disconnect connector S02, and connect T-adapter to male side.
3. Turn the working lamp switch to ON/OFF position to perform troubleshoot-
ing. (ON is available for both directions.)
Defective working lamp
5 OFF Min. 1 MΩ
switch Between S02 (male) (5)
and (6) ON Max. 1 Ω
Resistance
Between S02 (male) (5) OFF Min. 1 MΩ
and (4) ON Max. 1 Ω
1. Turn the starting switch to OFF position.
2. Disconnect connector D01, and connect T-adapter to male side.
REMARK
Measure it with diode range of multimeter.
Defective diode
6 No continui-
(internal open or short Between D01 (male) (3) (+) and (7) (-)
ty
circuit)
Between D01 (male) (7) (+) and (3) (-) Continuity
Continuity
No continui-
Between D01 (male) (4) (+) and (8) (-)
ty
Between D01 (male) (8) (+) and (4) (-) Continuity

40-260 PC45MR-5, PC55MR-5

E-32 NONE OF WORKING LAMP, TRAVEL LAMP, OR ADDITIONAL
40 TROUBLESHOOTING LAMP DOES NOT LIGHT UP (CAB SPEC)

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect connectors W02, F22A, and F22B, and connect T-adapter to
each female side.
3. Turn the starting switch to ON position.
4. Turn on the working lamp switch.
Between W02 (female) (A) and (B) 10 to 15 V
Voltage Between F22A (female) (1) and (2) 10 to 15 V
Between F22B (female) (1) and (2) 10 to 15 V
If no failure is found by preceding checks, this check is not required.
1. Turn the starting switch to OFF position.
2. Disconnect connector W01, and connect T-adapter to female side.
3. Turn the starting switch to ON position.
4. Turn on the working lamp switch.
Between W01 (female) (1) and (2) 10 to 15 V
Voltage
Open or short circuit in Between F22 (female) (1) and (2) 10 to 15 V
7
wiring harness
If no failure is found by preceding checks, this check is not required.
1. Turn the starting switch to OFF position.
2. Disconnect connectors R04 and R05, and connect T-adapter to each fe-
male side.
3. Turn the starting switch to ON position.
4. Turn on the working lamp switch.
Between R04 (female) (1) and (2) 10 to 15 V
Between R04 (female) (3) and (2) 10 to 15 V
Voltage
Between R05 (female) (1) and (2) 10 to 15 V
Between R05 (female) (3) and (2) 10 to 15 V
If no failure is found by preceding checks, this check is not required.
1. Turn the starting switch to OFF position.
2. Disconnect connector S02, and connect T-adapter to female side.
3. Turn the starting switch to ON position.
Voltage Between S02 (female) (5) and (2) 10 to 15 V

PC45MR-5, PC55MR-5 40-261

E-32 NONE OF WORKING LAMP, TRAVEL LAMP, OR ADDITIONAL
LAMP DOES NOT LIGHT UP (CAB SPEC) 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

If no failure is found by check on cause 7, this check is not required.
1. Turn the starting switch to OFF position.
2. Remove fuses FB1 (1) and FB1 (11).
3. Disconnect connectors S02, D01, R04, R05, F03, W02, F22A, and F22B,
and connect T-adapter to each female side.
Between W02 (female) (B) and ground Max. 1 Ω
Between F22A (female) (1) and ground Max. 1 Ω
Between F22B (female) (1) and ground Max. 1 Ω
Between W02 (female) (A) and R04 (female) (5) Max. 1 Ω
Between F22A (female) (2) and R05 (female) (5) Max. 1 Ω
Between F22B (female) (2) and R05 (female) (5) Max. 1 Ω
Open circuit in wiring har- Between R04 (female) (1) and D01 (female) (3) Max. 1 Ω
ness
8 Between R04 (female) (1) and D01 (female) (4) Max. 1 Ω
(wire breakage or defec-
tive contact of connector) Between R05 (female) (1) and D01 (female) (3) Max. 1 Ω

Resistance Between R05 (female) (1) and D01 (female) (4) Max. 1 Ω
Between R04 (female) (2) and ground Max. 1 Ω
Between R05 (female) (2) and ground Max. 1 Ω
Between R04 (female) (3) and FB1 (11) Max. 1 Ω
Between R05 (female) (3) and FB1 (11) Max. 1 Ω
Between D01 (female) (7) and each of S02 (female)
Max. 1 Ω
(1) and (6)
Between S02 (female) (2) and ground Max. 1 Ω
Between D01 (female) (8) and each of S02 (female)
Max. 1 Ω
(3) and (4)
Between S02 (female) (5) and FB1 (1) Max. 1 Ω
If no failure is found by check on cause 7, this check is not required.
1. Turn the starting switch to OFF position.
2. Remove fuses FB1 (1) and FB1 (11).
Ground fault in wiring 3. Disconnect connectors S02, D01, R04, R05, F03, W02, F22A, and F22B,
harness and connect T-adapter to female side of S02 and R04.
9
(contact with ground cir- Between ground and R04 (female) (1) or R05 (1) Min. 1 MΩ
cuit)
Between ground and R04 (female) (3) or R05 (3) Min. 1 MΩ
Resistance
Between ground and R04 (female) (5) or R05 (5) Min. 1 MΩ
Between S02 (female) (5) and ground Min. 1 MΩ

40-262 PC45MR-5, PC55MR-5

E-32 NONE OF WORKING LAMP, TRAVEL LAMP, OR ADDITIONAL
40 TROUBLESHOOTING LAMP DOES NOT LIGHT UP (CAB SPEC)

Circuit diagram related to working lamp, travel lamp, and additional lamp

PC45MR-5, PC55MR-5 40-263

E-33 WHEN WIPER SWITCH IS OPERATED, WINDSHIELD WIPER
DOES NOT OPERATE 40 TROUBLESHOOTING

E-33 WHEN WIPER SWITCH IS OPERATED, WINDSHIELD WIPER DOES

NOT OPERATE
Failure Wiper does not operate even if wiper switch is operated.
Related When engine starts (If engine does not start, perform troubleshooting for “Engine does not start (En-
information gine does not crank)” in E mode first.

No. Cause Procedure, measuring location, criteria and remarks

1 Defective fuse If fuse FB1 (No.4) is blown out, circuit probably has ground fault, etc.
1. Turn the starting switch to OFF position.
2. Disconnect terminal of wiper switch.
Between terminal (1) and
OFF: (No operation) Max. 1 Ω
(2)
Between terminal (2) and
Defective wiper switch Resistance ON: (First stage) Max. 1 Ω
(3)
2 (internal open circuit or
defective contact) Between terminal (3) and
WASH: (2nd stage) Max. 1 Ω
(4)
1. Install terminal wiring, and perform troubleshooting when starting switch is
in ON position.
Between terminal (2) and
Voltage ON: (First stage) 10 to 15 V
ground
1. Turn the starting switch to OFF position.
2. Disconnect terminal of wiper switch.
Open circuit in wiring har- Between FB1 (4) and F24 (1), between F24 (1) and
ness Max. 1 Ω
F27 (4), between F27 (4) and wiper switch terminal (3)
3
(Wire breakage or defec- Between wiper switch terminal (2) and wiper motor (+) Max. 1 Ω
tive contact of connector) Resistance
Between wiper motor (-) and F27 (1), between F27 (1)
and F24 (2), between F24 (2) and F02 (2), between Max. 1 Ω
F02 (2) and ground
1. Turn the starting switch to OFF position.
Ground fault in wiring 2. Disconnect terminal of wiper switch.
harness Between ground and FB1 (4) or wiper switch terminal
4 Min. 1 MΩ
(Contact with ground cir- (3)
cuit) Resistance
Between ground and wiper switch terminal (2) or wiper
Min. 1 MΩ
motor (+)

40-264 PC45MR-5, PC55MR-5

E-33 WHEN WIPER SWITCH IS OPERATED, WINDSHIELD WIPER
40 TROUBLESHOOTING DOES NOT OPERATE

Circuit diagram related to wiper

PC45MR-5, PC55MR-5 40-265

E-34 WHEN WINDOW WASHER SWITCH IS OPERATED, WINDOW
WASHER DOES NOT OPERATE 40 TROUBLESHOOTING

E-34 WHEN WINDOW WASHER SWITCH IS OPERATED, WINDOW WASH-

ER DOES NOT OPERATE
Failure Window washer does not operate even if window washer switch is operated.
• Before troubleshooting, check the fluid level inside of window washer tank.
Related
• When wiper operates. (If wiper does not operate, perform troubleshooting for “Wiper does
information
not operate even if wiper switch is operated” in E mode first.)

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect connector M02, and connect T-adapter.
Resistance Between M02 (male) (1) and ground Min. 1 MΩ
Defective washer motor
1 (internal defective con- 1. Turn the starting switch to OFF position.
tact) 2. Connect T-adapter to connector M02.
3. Turn the starting switch to ON position.
Voltage Between M02 (female) (2) and ground 10 to 15 V
1. Turn the starting switch to OFF position.
2. Disconnect terminal of wiper switch.
Between terminal (3) and
Defective wiper switch Resistance WASH: (2nd stage) Max. 1 Ω
(4)
2 (Internal defective con-
tact) 1. Install terminal wiring, and perform troubleshooting when starting switch is
in ON position.
Between terminal (4) and
Voltage WASH: (2nd stage) 10 to 15 V
ground
1. Turn the starting switch to OFF position.
2. Disconnect connector M02 and wiper switch terminal, and connect T-
Open circuit in wiring har- adapter to female side of M02.
3 ness (wire breakage or Between M02 (female) (2) and F03 (4), between F03
defective contact) (4) and F24 (3), between F24 (3) and F27 (3), between Max. 1 Ω
Resistance F27 (3) and wiper switch terminal (4)
Between M02 (female) (1) and ground Max. 1 Ω
1. Turn the starting switch to OFF position.
Ground fault in wiring 2. Disconnect connector M02 and wiper switch terminal, and connect T-
4 harness (contact with adapter to female side of M02.
ground circuit)
Between ground and M02 (2) or wiper switch terminal
Resistance Min. 1 MΩ
(4)

40-266 PC45MR-5, PC55MR-5

E-34 WHEN WINDOW WASHER SWITCH IS OPERATED, WINDOW
40 TROUBLESHOOTING WASHER DOES NOT OPERATE

Circuit diagram related to windshield washer

PC45MR-5, PC55MR-5 40-267

E-35 TRAVEL INDICATOR IS NOT DISPLAYED PROPERLY WITH
MONITORING FUNCTION 40 TROUBLESHOOTING

E-35 TRAVEL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITOR-

ING FUNCTION
Failure "Travel" is not displayed correctly with monitoring function.
Related
Monitoring code: 01900
information

No. Cause Procedure, measuring location, criteria and remarks

Defective travel PPC oil Perform troubleshooting for failure code [DHS5MA].
pressure sensor system
1
(internal open or short
circuit)

40-268 PC45MR-5, PC55MR-5

E-36 Swing or Arm IN IS NOT DISPLAYED NORMALLY IN MONITOR-
40 TROUBLESHOOTING ING FUNCTION

E-36 Swing or Arm IN IS NOT DISPLAYED NORMALLY IN MONITORING

FUNCTION
Failure "Swing or Arm IN" is not displayed normally in monitoring function.
Related
Monitoring code: 01900
information

No. Cause Procedure, measuring location, criteria and remarks

Defective swing PPC oil Perform troubleshooting for failure codes [DHS1MA].
pressure sensor system
1
(Internal open or short
circuit)

PC45MR-5, PC55MR-5 40-269

E-37 Work Equipment IS NOT DISPLAYED NORMALLY IN MONITOR-
ING FUNCTION 40 TROUBLESHOOTING

E-37 Work Equipment IS NOT DISPLAYED NORMALLY IN MONITORING

FUNCTION
Failure "Work Equipment" is not displayed normally in monitoring function.
Related
Monitoring code: 01900
information

No. Cause Procedure, measuring location, criteria and remarks

Be ready with starting switch in OFF position, then start the engine to perform trou-
bleshooting.
R.H. and L.H. work equip-
Defective work equipment control lever: NEU- Min. 1 MΩ
ment PPC oil pressure TRAL
1 switch
Between P01 (male) (1) R.H. and L.H. work equip-
(Internal open or short Resistance
and (2) ment control lever: Oper-
circuit)
ate any of boom, arm,
Max. 1 Ω
bucket, service, blade
control lever, and boom
swing control pedal.
1. Turn the starting switch to OFF position.
Open circuit in wiring har- 2. Disconnect connectors CP01 and P01, and connect T-adapter to each fe-
ness male side.
2
(wire breakage or defec-
Between CP01 (female) (21) and P01 (female) (1) Max. 1 Ω
tive contact of connector) Resistance
Between P01 (female) (2) and ground (T02) Max. 1 Ω
1. Turn the starting switch to OFF position.
Ground fault in wiring
2. Disconnect connectors CP01 and P01, and connect T-adapters to female
harness
3 side or P01.
(contact with ground cir-
cuit) Between ground and CP01 (female) (21) or P01 (fe-
Resistance Min. 1 MΩ
male) (1)
1. Turn the starting switch to OFF position.
2. Disconnect connectors CP01 and P01, and connect T-adapter to either fe-
Short circuit or hot short
male side.
4 circuit in wiring harness
3. Turn the starting switch to ON position.
(contact with 12 V circuit)
Between ground and CP01 (female) (21) or P01 (fe-
Voltage Max. 1 V
male) (1)
Be ready with starting switch in OFF position, then start the engine to perform trou-
bleshooting.
R.H. and L.H. work equip-
ment control lever: NEU- Min. 1 MΩ
TRAL
Defective machine con-
5
troller Between CP01 (female) R.H. and L.H. work equip-
Resistance ment control lever: Oper-
(21) and ground
ate any of boom, arm,
Max. 1 Ω
bucket, service, blade
control lever, and boom
swing control pedal.

40-270 PC45MR-5, PC55MR-5

E-37 Work Equipment IS NOT DISPLAYED NORMALLY IN MONITOR-
40 TROUBLESHOOTING ING FUNCTION

Circuit diagram related to work equipment PPC oil pressure switch

PC45MR-5, PC55MR-5 40-271

E-38 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY 40 TROUBLESHOOTING

E-38 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY

Failure KOMTRAX system does not operate normally.
• Perform following troubleshooting if administrator of KOMTRAX system requests to check
whether failure occurs in system on machine.
• Even when KOMTRAX system is defective, no problem is displayed on machine.
Related • All troubleshooting can be checked on the service menu of the machine monitor.
information • For checking of Terminal Status, see Testing and adjusting, “METHOD FOR CONFIRM-
ING KOMTRAX SETTINGS (TERMINAL STATUS)”.
• For checking of GPS & Communication State, see Testing and adjusting, “METHOD FOR
CONFIRMING KOMTRAX SETTINGS (GPS AND COMMUNICATION STATUS)”.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to ON position.
2. Display Terminal Status screen.
1 Transmitting error 1
Monitoring display Check item: KOMTRAX State of radio station es-
Communication tablishment
1. Turn starting switch to ON position.
2. Display GPS & Communication Status screen.
N ###.##.## (Latitude)
Defective GPS position-
2 Monitoring display Check item: Positioning E ###.##.## (Longitude)
ing
Positioning in Progress
If the latitude and longitude are not displayed within 5 minutes in an open-sky area,
call the KOMTRAX service hot-line for advice.
1. Turn starting switch to ON position.
2. Display GPS & Communication Status screen.
Defective communication Monitoring display Check item: Communica- Communication reception
3
environment tion range level 1 to 3
Contact KOMTRAX service hot-line if communication reception range is not within
level 1 to 3.
1. Turn starting switch to ON position.
2. Display GPS & Communication Status screen.
4 Transmitting error 2
Monitoring display Check item: Number of 0 to 100 (normally 0)
message(s) not yet sent

40-272 PC45MR-5, PC55MR-5

INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H
40 TROUBLESHOOTING MODE)

TROUBLESHOOTING FOR HYDRAULIC AND MECHANI-

CAL SYSTEMS (H MODE)
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE)
The following information is summarized in the troubleshooting table. Before performing troubleshooting, under-
stand that information fully.
Failure Failure symptom that appears on machine
Related infor-
Information on occurred failure or troubleshooting
mation

No. Cause Procedure, measuring location, criteria, and remarks

1
2 <Contents of description>
Probable cause of failure
3 (Each number is serial num- • Criteria to determine probable causes
ber, not priority sequence.) • Remarks for determination of probable cause
4
5

PC45MR-5, PC55MR-5 40-273

H-1 ALL WORK EQUIPMENT, TRAVEL, SWING OR BLADE DO NOT
OPERATE 40 TROUBLESHOOTING

H-1 ALL WORK EQUIPMENT, TRAVEL, SWING OR BLADE DO NOT OPER-

ATE
Failure All work equipment, travel, swing or blade do not operate
• Set working mode to power mode (P), and perform all troubleshooting with power mode
(P).
Related • Check that the oil level in hydraulic tank is correct.
information • Perform troubleshooting with the hydraulic oil temperature at 45 to 55 °C.
• Before performing troubleshooting, check that electrical system (solenoid circuit) is nor-
mal.

No. Cause Procedure, measuring location, criteria and remarks

Be ready with engine stopped, then perform troubleshooting with engine at high
idle.
0 MPa
Lock lever: LOCK
{0 kg/cm2}
Malfunction of PPC lock
1 Solenoid
solenoid valve 2.94
valve outlet (+0.49/-0.1)
pressure Lock lever: FREE MPa {30
(+5/-1)
kg/cm2}
Be ready with engine stopped, then perform troubleshooting with engine at high
idle.
4.90
Incorrect adjustment or Relief pres- (+0.59/-0.1)
2 malfunction of relief valve sure of con- All control levers: NEUTRAL MPa {50
in control circuit trol circuit (+6/-1)
kg/cm2}
When pressure cannot be adjusted to normal level, control relief valve may mal-
function or may have internal defect. Check it.
Clogged suction strainer If no failure is found by preceding checks, the strainer or return filter may be clog-
3
or return filter ged. Check it.
4 Defective control pump If no failure is found by preceding checks, control pump may be defective.
Disconnect the discharge hose of main pump and crank the engine with starting
motor, and check if the oil flows out from the discharge port.
Defective main pump, REMARK
5
drive shaft or damper
No-Injection cranking is required. For details of procedure, see TESTING AND
ADJUSTING, “TEST COMPRESSION PRESSURE”.

40-274 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING H-2 ALL WORK EQUIPMENTS OR TRAVEL DOES NOT OPERATE

H-2 ALL WORK EQUIPMENTS OR TRAVEL DOES NOT OPERATE

Failure All work equipments or travel does not operate
• Set working mode to power mode (P), and perform all troubleshooting with power mode
(P).
Related
• Check that the oil level in hydraulic tank is correct.
information
• Perform troubleshooting with the hydraulic oil temperature at 45 to 55 °C.
• Check that swing and blade operations are normal.

No. Cause Procedure, measuring location, criteria and remarks

PC45MR-5, PC55MR-5 40-275

H-3 TRAVEL OR BLADE DOES NOT OPERATE 40 TROUBLESHOOTING

H-3 TRAVEL OR BLADE DOES NOT OPERATE

Failure Travel or blade does not operate.
• Set working mode to power mode (P), and perform all troubleshooting with power mode
(P).
Related
• Check that the oil level in hydraulic tank is correct.
information
• Perform troubleshooting with the hydraulic oil temperature at 45 to 55 °C.
• Check that all work equipments and swing operations are normal.

No. Cause Procedure, measuring location, criteria and remarks

1. Engine stopped
2. Plug the hydraulic hose to travel or blade circuit at control valve side
3. Engine at high idle
26.5 ±
Main pump
Travel lever circuit (at the side where hose is discon- 0.98 MPa
relief pres-
nected) {270 ±
Defective center swivel sure
1 10 kg/cm2}
joint
21.6
Swing and
(+0.98/-0.49
blade pump Blade lever circuit (at the side where hose is discon-
) MPa {220
relief pres- nected)
(+10/-5)
sure
kg/cm2}
If the oil pressure in all hydraulic circuits is low in all the preceding checks, center
swivel joint may be defective. Check it.

40-276 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING H-4 SWING OR BLADE DOES NOT OPERATE

H-4 SWING OR BLADE DOES NOT OPERATE

Failure Swing or blade does not operate.
• Set working mode to power mode (P), and perform all troubleshooting with power mode
(P).
Related
• Check that the oil level in hydraulic tank is correct.
information
• Perform troubleshooting with the hydraulic oil temperature at 45 to 55 °C.
• Check that all work equipments and swing operations are normal.

No. Cause Procedure, measuring location, criteria and remarks

Be ready with engine stopped, then perform troubleshooting with engine at high
idle.
21.6
Swing and
Improper adjustment or (+0.98/-0.49
blade pump
1 malfunction of swing and Blade LOWER relief ) MPa {220
relief pres-
blade pump relief valve (+10/-5)
sure
kg/cm2}
When pressure cannot be adjusted to normal level, relief valve for swing and blade
pump may malfunction or may have internal defect. Check it.
Disconnect the discharge hose of swing and blade pump and crank the engine with
Defective swing and starting motor, and check if the oil flows out from the discharge port.
2 blade pump, drive shaft REMARK
or coupling No-Injection cranking is required. For details of procedure, see TESTING AND
ADJUSTING, “TEST COMPRESSION PRESSURE”.

PC45MR-5, PC55MR-5 40-277

H-5 ALL WORK EQUIPMENT, TRAVEL, SWING AND BLADE SPEED
OR POWER IS LOW 40 TROUBLESHOOTING

H-5 ALL WORK EQUIPMENT, TRAVEL, SWING AND BLADE SPEED OR

POWER IS LOW
Failure All work equipment, travel, swing and blade speed or power is low
• Set working mode to power mode (P), and perform all troubleshooting with power mode
(P).
• Check that the oil level in hydraulic tank is correct.
• Perform troubleshooting with the hydraulic oil temperature at 45 to 55 °C.
Related
• Before performing troubleshooting, check that electrical system (solenoid circuit) is nor-
information
mal.
• If failure codes are displayed, perform troubleshooting of failure codes displayed first.
(DXA8KA and DXA8KB)
• It is not abnormal that the phenomenon disappears by increasing the engine speed.

No. Cause Procedure, measuring location, criteria and remarks

40-278 PC45MR-5, PC55MR-5

H-6 ALL WORK EQUIPMENT AND TRAVEL SPEED OR POWER IS
40 TROUBLESHOOTING LOW

H-6 ALL WORK EQUIPMENT AND TRAVEL SPEED OR POWER IS LOW

Failure All work equipment and travel speed or power is low
• Set working mode to power mode (P), and perform all troubleshooting with power mode
(P).
Related • Check that the oil level in hydraulic tank is correct.
information • Perform troubleshooting with the hydraulic oil temperature at 45 to 55 °C.
• Check that swing and blade operations are normal.
• It is not abnormal that the phenomenon disappears by increasing the engine speed.

No. Cause Procedure, measuring location, criteria and remarks

When pressure cannot be adjusted to normal level, main relief valve may malfunc-
tion or may have internal defect. Check it.
Be ready with engine stopped, then perform troubleshooting with engine at high
Improper adjustment or
idle.
1 malfunction of main relief
valve 26.5 ±
Main relief • Arm IN relief 0.98 MPa
pressure • Travel hydraulic relief {270 ±
10 kg/cm2}
Be ready with engine stopped, then perform troubleshooting with engine at high
idle.
Malfunction of unload 2.9±0.49
2
valve Unload MPa
All control levers in NEUTRAL
pressure {30±5
kg/cm2}
Be ready with engine stopped, then perform troubleshooting with engine at high
idle.
Differential pressure be- 1.57±0.1
LS differen- tween pump discharged MPa
Bucket CURL operated
tial pressure pressure and LS valve in- {16±1
put pressure kg/cm2}
Defective adjustment and
3 Lever oper- Differential pressure be- 2.9(+0.98/-0
malfunction of LS valve
ation and oil All control levers in NEU- tween pump discharged ) MPa
pressure ra- TRAL pressure and LS valve in- {30(+10/-0)
tio put pressure kg/cm2}
When pressure cannot be adjusted to normal level, the LS valve may have mal-
function. Check for malfunction of the LS valve (fatigue of spring), internal defect
(seized LS spool, stick), etc.
Defective adjustment and When pressure cannot be adjusted to normal level, check for malfunction of the PC
4
malfunction of PC valve valve (fatigue of spring), internal defect (seized PC spool, stick), etc.
Clogged orifice or filter in Check if orifice and filter in pump servo device is not clogged.
5
pump servo device
If failure code is still displayed after above checks, piston pump may have malfunc-
6 Defective piston pump
tion, internal defect, etc.

PC45MR-5, PC55MR-5 40-279

H-7 TRAVEL AND BLADE SPEED OR POWER IS LOW 40 TROUBLESHOOTING

H-7 TRAVEL AND BLADE SPEED OR POWER IS LOW

Failure Travel and blade speed or power is low
• Set working mode to power mode (P), and perform all troubleshooting with power mode
(P).
Related • Check that the oil level in hydraulic tank is correct.
information • Perform troubleshooting with the hydraulic oil temperature at 45 to 55 °C.
• Check that all work equipments and swing operations are normal.
• It is not abnormal that the phenomenon disappears by increasing the engine speed.

No. Cause Procedure, measuring location, criteria and remarks

40-280 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING H-8 SWING AND BLADE SPEED OR POWER IS LOW

H-8 SWING AND BLADE SPEED OR POWER IS LOW

Failure Swing and blade speed is low or power is low.
• Set working mode to power mode (P), and perform all troubleshooting with power mode
(P).
Related • Check that the oil level in hydraulic tank is correct.
information • Perform troubleshooting with the hydraulic oil temperature at 45 to 55 °C.
• Check that all work equipments and travel operations are normal.
• It is not abnormal that the phenomenon disappears by increasing the engine speed.

No. Cause Procedure, measuring location, criteria and remarks

Be ready with engine stopped, then perform troubleshooting with engine at high
idle.
21.6
Swing and
Improper adjustment or (+0.98/-0.49
blade pump
1 malfunction of swing and Blade LOWER relief ) MPa {220
relief pres-
blade pump relief valve (+10/-5)
sure
kg/cm2}
When pressure cannot be adjusted to normal level, relief valve for swing and blade
pump may malfunction or may have internal defect. Check it.
Defective swing and When oil pressure is not normal even after adjustment or replacement, perform-
2
blade pump ance deterioration of the swing and blade pump may be occurred.

PC45MR-5, PC55MR-5 40-281

H-9 FINE CONTROL PERFORMANCE OR RESPONSE IS POOR 40 TROUBLESHOOTING

H-9 FINE CONTROL PERFORMANCE OR RESPONSE IS POOR

Failure Fine control performance or response is poor.
Related • Perform all troubleshooting with working mode to be set to power mode (P).
information • Perform troubleshooting with the hydraulic oil temperature at 45 to 55 °C.

No. Cause Procedure, measuring location, criteria and remarks

Clogging of LS circuit ori- LS circuit orifice may be clogged. Check it.
1
fice
Be ready with engine stopped, then perform troubleshooting with engine at high
idle.
Differential pressure be- 1.57±0.1
LS differen- tween pump discharged MPa
Bucket CURL operated
tial pressure pressure and LS valve in- {16±1
put pressure kg/cm2}
Defective adjustment and
2 Lever oper- Differential pressure be- 2.9(+0.98/-0
malfunction of LS valve
ation and oil All control levers in NEU- tween pump discharged ) MPa
pressure ra- TRAL pressure and LS valve in- {30(+10/-0)
tio put pressure kg/cm2}
When pressure cannot be adjusted to normal level, the LS valve may have mal-
function. Check for malfunction of the LS valve (fatigue of spring), internal defect
(seized LS spool, stick), etc.
Malfunction of servo pis- Check if orifice and filter in pump servo device is not clogged.
3
ton
Be ready with engine stopped, then perform troubleshooting with engine at high
idle.
Malfunction of unload 2.9±0.49
4
valve Unload MPa
All control levers in NEUTRAL
pressure {30±5
kg/cm2}
Clogged main pump ori- If no failure is found by above checks, main pump orifice plug may be clogged.
5
fice plug Check it.

40-282 PC45MR-5, PC55MR-5

H-10 UNUSUAL NOISE IS HEARD FROM AROUND HYDRAULIC
40 TROUBLESHOOTING PUMP

H-10 UNUSUAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP

Failure Unusual noise is heard from around hydraulic pump.
Related • Perform all troubleshooting with working mode to be set to power mode (P).
information • Perform troubleshooting with the hydraulic oil temperature at 45 to 55 °C.

No. Cause Procedure, measuring location, criteria and remarks

Check the hydraulic oil level.
Lowered hydraulic oil lev- REMARK
1
el
If the oil level is low and there is no trace of external leakage, it is possible that it is
flowing into the flywheel chamber due to pump shaft seal damage.
2 Defective hydraulic oil Air may have entered into hydraulic oil and check for bubbles or milky oil, etc.
Clogged hydraulic tank Hydraulic tank breather may be clogged and pressure inside the tank may become
3
breather negative. Check it.
Clogged hydraulic oil Hydraulic tank strainer may be clogged and pressure of suction circuit may become
4
tank strainer negative. Check it.
Clogged hydraulic tank Hydraulic tank return filter may be clogged and pressure of suction circuit may be-
5
return filter come negative. Check it.
If any metallic matters are adhered in preceding check cause 4 and 5, piston pump
6 Defective piston pump
may have internal defect.

PC45MR-5, PC55MR-5 40-283

H-11 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS 40 TROUBLESHOOTING

H-11 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS

Failure Engine speed drops largely or engine stops.
• Set working mode to power mode (P), and perform all troubleshooting with power mode
(P).
Related
• Perform troubleshooting with the hydraulic oil temperature at 45 to 55 °C.
information
• If failure codes are displayed, perform troubleshooting of failure codes displayed first.
(DXA8KA and DXA8KB)

No. Cause Procedure, measuring location, criteria and remarks

Be ready with engine stopped, then perform troubleshooting with engine at high
idle.
26.5 ±
Incorrect adjustment or
Main relief 0.98 MPa
1 malfunction of main relief Arm IN relief
pressure {270 ±
valve
10 kg/cm2}
When pressure cannot be adjusted to normal level, main relief valve may malfunc-
tion or may have internal defect. Check it.
Defective adjustment and When pressure cannot be adjusted to normal level, check for malfunction of the PC
2
malfunction of PC valve valve (fatigue of spring), internal defect (seized PC spool, stick), etc.
Be ready with engine stopped, then perform troubleshooting with engine at high
idle.
Differential pressure be- 1.57±0.1
LS differen- tween pump discharged MPa
Bucket CURL operated
tial pressure pressure and LS valve in- {16±1
put pressure kg/cm2}
Defective adjustment and
3 Lever oper- Differential pressure be- 2.9(+0.98/-0
malfunction of LS valve
ation and oil All control levers in NEU- tween pump discharged ) MPa
pressure ra- TRAL pressure and LS valve in- {30(+10/-0)
tio put pressure kg/cm2}
When pressure cannot be adjusted to normal level, the LS valve may have mal-
function. Check for malfunction of the LS valve (fatigue of spring), internal defect
(seized LS spool, stick), etc.
Be ready with engine stopped, then perform troubleshooting with engine at high
idle.
21.6
Swing and
Incorrect adjustment or (+0.98/-0.49
blade pump
4 malfunction of relief valve Blade LOWER relief ) MPa {220
relief pres-
for gear pump (+10/-5)
sure
kg/cm2}
When pressure cannot be adjusted to normal level, relief valve for swing and blade
pump may malfunction or may have internal defect. Check it.
Clogged orifice or filter in Check if orifice and filter in pump servo device is not clogged.
5
pump servo device
If failure code is still displayed after above checks, piston pump may have malfunc-
6 Defective piston pump
tion, internal defect, etc.
If failure code is still displayed after above checks, engine performance may lower.
7 Defective engine system
Perform troubleshooting by referring to “S mode” troubleshooting.
Clogged hydraulic oil Hydraulic tank strainer may be clogged and pressure of suction circuit may become
8
tank strainer negative. Check it.

40-284 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING H-11 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS

No. Cause Procedure, measuring location, criteria and remarks

Clogged hydraulic tank Hydraulic tank return filter may be clogged and pressure of suction circuit may be-
9
return filter come negative. Check it.

PC45MR-5, PC55MR-5 40-285

H-12 ALL WORK EQUIPMENTS SPEED OR POWER IS LOW 40 TROUBLESHOOTING

H-12 ALL WORK EQUIPMENTS SPEED OR POWER IS LOW

Failure All work equipments speed or power is low
• Set working mode to power mode (P), and perform all troubleshooting with power mode
(P).
Related • Check that the oil level in hydraulic tank is correct.
information • Perform troubleshooting with the hydraulic oil temperature at 45 to 55 °C.
• Check that travel, swing, and blade operations are normal.
• It is not abnormal that the phenomenon disappears by increasing the engine speed.

No. Cause Procedure, measuring location, criteria and remarks

Be ready with engine stopped, then perform troubleshooting with engine at high
idle.
• Right and left work equipment control lever:
NEUTRAL 0 MPa
Defective sealing of logic
{0 kg/cm2}
valve and check valve for • Boom swing control pedal: NEUTRAL
1 PPC valve
control circuit pressure
pilot outlet pres- 2.94
sure • Right and left work equipment control lever: (+0.49/-0.1)
Both directions MPa {30
• Boom swing control pedal: Right swing (+5/-1)
kg/cm2}

40-286 PC45MR-5, PC55MR-5

H-13 ALL WORK EQUIPMENTS AND BLADE SPEED OR POWER IS
40 TROUBLESHOOTING LOW

H-13 ALL WORK EQUIPMENTS AND BLADE SPEED OR POWER IS LOW

Failure All work equipments and blade speed or power is low
• Set working mode to power mode (P), and perform all troubleshooting with power mode
(P).
Related • Check that the oil level in hydraulic tank is correct.
information • Perform troubleshooting with the hydraulic oil temperature at 45 to 55 °C.
• Check that travel and swing operations are normal.
• It is not abnormal that the phenomenon disappears by increasing the engine speed.

No. Cause Procedure, measuring location, criteria and remarks

Be ready with engine stopped, then perform troubleshooting with engine at high
idle.
26.5 ±
Main pump • Work equipment control lever: Both directions 0.98 MPa
relief pres-
• Boom swing control pedal: Right swing {270 ±
sure
10 kg/cm2}
21.6
Swing and
Malfunction of centralized (+0.98/-0.49
1 blade pump
safety valve Blade control lever: LOWER ) MPa {220
relief pres-
(+10/-5)
sure
kg/cm2}
If the oil pressure in all hydraulic circuits is low in all the preceding checks, central-
ized safety valve may be defective. Check it.
REMARK
Centralized safety valve works on both sides of head and bottom for boom, arm,
and bucket, and it works on head side for swing, and bottom side for blade.

PC45MR-5, PC55MR-5 40-287

H-14 BLADE DOES NOT OPERATE 40 TROUBLESHOOTING

H-14 BLADE DOES NOT OPERATE

Failure Blade does not operate.
• Set working mode to power mode (P), and perform all troubleshooting with power mode
(P).
• Check that the oil level in hydraulic tank is correct.
Related • Perform troubleshooting with the hydraulic oil temperature at 45 to 55 °C.
information • If swing does not operate, perform troubleshooting for “SWING AND BLADE DO NOT OP-
ERATE” in H mode first.
• If travel does not operate, perform troubleshooting for “TRAVEL AND BLADE DO NOT
OPERATE” in H mode first.

No. Cause Procedure, measuring location, criteria and remarks

Be ready with engine stopped, then perform troubleshooting with engine at high
idle.
0 MPa
Blade control lever: NEUTRAL
{0 kg/cm2}
1 Malfunction of PPC valve PPC valve
2.94
outlet pres- (+0.49/-0.1)
sure Blade control lever: RAISE and LOWER MPa {30
(+5/-1)
kg/cm2}
Release remaining pressure from hydraulic tank and piping, and then perform trou-
bleshooting with engine stopped.
• Check if the bucket spool is stuck or seized with control valve body. (Spool
Malfunction of blade con- should move smoothly.)
2
trol valve (spool)
• Remove the blade spool from valve body, and check it for flaw and sticking
of dirt.
• When restoring, be careful about the dirt to enter.
Be ready with engine stopped, then perform troubleshooting with engine at high
idle.
3 Defective blade cylinder Leakage of
blade cylin- Blade LOWER relief 10 cc/min
der
Defective blade cylinder Blade cylinder or blade may be deformed. Check it.
4
or blade

40-288 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING H-15 ALL WORK EQUIPMENTS DO NOT OPERATE

H-15 ALL WORK EQUIPMENTS DO NOT OPERATE

Failure All work equipments do not operate.
• Set working mode to power mode (P), and perform all troubleshooting with power mode
(P).
Related
• Check that the oil level in hydraulic tank is correct.
information
• Perform troubleshooting with the hydraulic oil temperature at 45 to 55 °C.
• Check that travel, swing, and blade operations are normal.

No. Cause Procedure, measuring location, criteria and remarks

PC45MR-5, PC55MR-5 40-289

H-16 ALL WORK EQUIPMENTS OR BLADE DO NOT OPERATE 40 TROUBLESHOOTING

H-16 ALL WORK EQUIPMENTS OR BLADE DO NOT OPERATE

Failure All work equipments or blade do not operate
• Set working mode to power mode (P), and perform all troubleshooting with power mode
(P).
Related
• Check that the oil level in hydraulic tank is correct.
information
• Perform troubleshooting with the hydraulic oil temperature at 45 to 55 °C.
• Check that travel and swing operations are normal.

No. Cause Procedure, measuring location, criteria and remarks

40-290 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING H-17 SPEED OR POWER OF BOOM IS LOW

H-17 SPEED OR POWER OF BOOM IS LOW

Failure Boom speed or power is low.
• Perform all troubleshooting with working mode to be set to power mode (P).
Related
• Check that oil level in hydraulic tank is normal.
information
• Perform troubleshooting with the hydraulic oil temperature at 45 to 55 °C.

No. Cause Procedure, measuring location, criteria and remarks

Be ready with engine stopped, then perform troubleshooting with engine at high
idle.
0 MPa
R.H. work equipment control lever: NEUTRAL
{0 kg/cm2}
Malfunction of R.H. PPC
1 PPC valve
valve (boom circuit) 2.94
outlet pres- (+0.49/-0.1)
sure R.H. work equipment control lever: Boom RAISE and
MPa {30
boom LOWER
(+5/-1)
kg/cm2}
Release remaining pressure from hydraulic tank and piping, and then perform trou-
bleshooting with engine stopped.

Malfunction of merge-di- • Check for stuck or seized main spool in merge-divider valve body (spool
2
vider main spool should move smoothly).
• Remove main spool from valve body and check it for defects and dirt.
When restoring, be careful about the dirt, etc. to enter.
Release remaining pressure from hydraulic tank and piping, and then perform trou-
bleshooting with engine stopped.
• Check if boom spool is stuck or seized with control valve body. (Spool
Malfunction of boom con-
3 should move smoothly.)
trol valve (spool)
• Remove boom spool from valve body, and check it for flaw and sticking of
dirt.
When restoring, be careful about the dirt, etc. to enter.
Malfunction of boom con- Pressure compensation valve of boom control valve may be defective. Check it.
4 trol valve (pressure com-
pensation valve)
Malfunction or defective Suction valve (bottom side) of boom control valve may malfunction or may have de-
5 sealing of boom control fective sealing. Check it.
valve (suction valve)

PC45MR-5, PC55MR-5 40-291

H-17 SPEED OR POWER OF BOOM IS LOW 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

Release remaining pressure from hydraulic tank and piping, and then perform trou-
bleshooting with engine stopped.
• Check if pilot spool is stuck or seized with valve body.
• Remove pilot spool from valve body and check it for flaw and sticking of
dirt.
• When restoring, be careful about the dirt to enter.
Malfunction of boom lock Be ready with engine stopped, then perform troubleshooting with engine at high
6 idle.
valve
26.5±1.5
Boom relief MPa
Boom RAISE relief
pressure {270±15
kg/cm2}
• If only the relief pressure of anti-drop valve side is low among the work
equipment relief pressures, safety valve may be defective. Replace safety
valve assembly.
Malfunction or defective Centralized safety valve and suction valve of control valve may malfunction or may
sealing of centralized have defective sealing. Check it.
7
safety valve and suction
valve
Malfunction of boom con- Lock valve of boom control valve may be defective. Check it.
8
trol valve (lock valve)
Be ready with engine stopped, then perform troubleshooting with engine at high
idle.
9 Defective boom cylinder Leakage of
boom cylin- Boom RAISE relief 10 cc/min
der

40-292 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING H-18 ARM SPEED OR POWER IS LOW

H-18 ARM SPEED OR POWER IS LOW

Failure Arm speed or power is low.
• Perform all troubleshooting with working mode to be set to power mode (P).
Related
• Check that oil level in hydraulic tank is normal.
information
• Perform troubleshooting with the hydraulic oil temperature at 45 to 55 °C.

No. Cause Procedure, measuring location, criteria and remarks

Be ready with engine stopped, then perform troubleshooting with engine at high
idle.
0 MPa
L.H. work equipment control lever: NEUTRAL
{0 kg/cm2}
Malfunction of L.H. PPC
1 PPC valve
valve (arm circuit) 2.94
outlet pres- (+0.49/-0.1)
sure L.H. work equipment control lever: Arm IN and arm
MPa {30
OUT
(+5/-1)
kg/cm2}
Release remaining pressure from hydraulic tank and piping, and then perform trou-
bleshooting with engine stopped.

Malfunction of arm con- • Check for stuck or seized arm spool in control valve body (spool should
3
trol valve (spool) move smoothly).
• Remove arm spool from valve body and check for defects and dirt.
When restoring, be careful about the dirt, etc. to enter.
Malfunction of arm con- Pressure compensation valve of arm control valve may be defective. Check it.
4 trol valve (pressure com-
pensation valve)
Malfunction or defective Suction valve (bottom and head side) of arm control valve may malfunction or may
5 sealing of arm control have defective sealing. Check it.
valve (suction valve)
Malfunction or defective Centralized safety valve and suction valve of control valve may malfunction or may
sealing of centralized have defective sealing. Check it.
6
safety valve and suction
valve
Be ready with engine stopped, then perform troubleshooting with engine at high
idle.
7 Defective arm cylinder
Leakage of
Arm IN relief 10 cc/min
arm cylinder

PC45MR-5, PC55MR-5 40-293

H-19 BUCKET SPEED OR POWER IS LOW 40 TROUBLESHOOTING

H-19 BUCKET SPEED OR POWER IS LOW

Failure Bucket speed or power is low.
• Perform all troubleshooting with working mode to be set to power mode (P).
Related
• Check that oil level in hydraulic tank is normal.
information
• Perform troubleshooting with the hydraulic oil temperature at 45 to 55 °C.

No. Cause Procedure, measuring location, criteria and remarks

Be ready with engine stopped, then perform troubleshooting with engine at high
idle.
0 MPa
R.H. work equipment control lever: NEUTRAL
{0 kg/cm2}
Malfunction of R.H. PPC
1 PPC valve
valve (bucket circuit) 2.94
outlet pres- (+0.49/-0.1)
sure R.H. work equipment control lever: Arm IN and arm
MPa {30
OUT
(+5/-1)
kg/cm2}
Release remaining pressure from hydraulic tank and piping, and then perform trou-
bleshooting with engine stopped.

Malfunction of bucket • Check for stuck or seized bucket spool in control valve body (spool should
3
control valve (spool) move smoothly).
• Remove bucket spool from valve body and check it for defects and dirt.
When restoring, be careful about the dirt, etc. to enter.
Malfunction of bucket Pressure compensation valve of bucket control valve may be defective. Check it.
4 control valve (pressure
compensation valve)
Malfunction or defective Suction valve (bottom and head side) of bucket control valve may malfunction or
5 sealing of bucket control may have defective sealing. Check it.
valve (suction valve)
Malfunction or defective Centralized safety valve and suction valve of control valve may malfunction or may
sealing of centralized have defective sealing. Check it.
6
safety valve and suction
valve
Be ready with engine stopped, then perform troubleshooting with engine at high
idle.
7 Defective bucket cylinder Leakage of
bucket cylin- Bucket CURL relief 10 cc/min
der

40-294 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING H-20 BLADE SPEED OR POWER IS LOW

H-20 BLADE SPEED OR POWER IS LOW

Failure Blade speed is low or power is low.
• Set working mode to power mode (P), and perform all troubleshooting with power mode
(P).
• Check that the oil level in hydraulic tank is correct.
Related • Perform troubleshooting with the hydraulic oil temperature at 45 to 55 °C.
information • If swing speed is slow, perform troubleshooting for “SWING AND BLADE SPEED IS LOW
OR POWER IS LOW” in H mode first.
• If travel speed is slow, perform troubleshooting for “TRAVEL AND BLADE SPEED IS LOW
OR POWER IS LOW” in H mode first.

No. Cause Procedure, measuring location, criteria and remarks

Be ready with engine stopped, then perform troubleshooting with engine at high
idle.
21.6
Swing and
Incorrect adjustment or (+0.98/-0.49
blade pump
1 malfunction of relief valve Blade LOWER relief ) MPa {220
relief pres-
for gear pump (+10/-5)
sure
kg/cm2}
When pressure cannot be adjusted to normal level, relief valve for swing and blade
pump may malfunction or may have internal defect. Check it.
Be ready with engine stopped, then perform troubleshooting with engine at high
idle.
0 MPa
Blade control lever: NEUTRAL
{0 kg/cm2}
Malfunction of blade PPC
2 PPC valve
valve (blade circuit) 2.94
outlet pres- (+0.49/-0.1)
sure Blade control lever: RAISE and LOWER MPa {30
(+5/-1)
kg/cm2}
Release remaining pressure from hydraulic tank and piping, and then perform trou-
bleshooting with engine stopped.
• Check if blade spool is stuck or seized with valve body. (Spool should
Malfunction of blade con- move smoothly.)
3
trol valve (spool)
• Remove blade spool from valve body, and check it for flaw and sticking of
dirt.
• When restoring, be careful about the dirt to enter.
Be ready with engine stopped, then perform troubleshooting with engine at high
idle.
4 Defective blade cylinder Leakage of
blade cylin- Blade LOWER relief 10 cc/min
der
Malfunction of load check Load check valve in the spool of control valve may malfunction. Check it.
5 valve in the spool of con-
trol valve

PC45MR-5, PC55MR-5 40-295

H-20 BLADE SPEED OR POWER IS LOW 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

Be ready with engine stopped, then perform troubleshooting with engine at high
idle.
21.6(+0.98/-
Blade relief 0.49) MPa
Blade RAISE relief
pressure {220(+10/-5)
kg/cm2}
Malfunction of blade
6 RAISE (suction-safety • If blade RAISE relief pressure is low, suction valve may be defective.
valve) Check it.
• Check that check valve of suction safety valve is seated on valve body in
position (it is not stuck halfway).
REMARK
Since relief pressure of safety valve cannot be adjusted when it is installed on
the machine, replace safety valve assembly if it is found to be defective.
Be ready with engine stopped, then perform troubleshooting with engine at high
idle.
21.6(+0.98/-
Blade relief 0.49) MPa
Blade LOWER relief
pressure {220(+10/-5)
kg/cm2}
Malfunction of blade • If only blade LOWER relief pressure is low between swing and blade
7 LOWER (suction safety LOWER relief pressure, suction valve may be defective. Check it.
valve)
• Check that check valve of suction valve is seated on valve body in position
(it is not stuck halfway).
• Remove check valve from valve body, and check it for flaw and sticking of
dirt.
• Check spring for fatigue and deformation.
• When restoring, be careful about the dirt to enter.
Performance deterioration, malfunction, and internal defect of the gear pump may
8 Defective gear pump
be occurred. Check it.
Be ready with engine stopped, then perform troubleshooting with engine at high
idle.
21.6
(+0.98/-0.49
Blade relief
Malfunction of centralized Blade LOWER relief ) MPa {220
9 pressure
safety valve (+10/-5)
kg/cm2}
If oil pressure does not become normal after adjustment, check safety valve for
malfunction (fatigued spring), internal defect (defective valve seat or entry of dirt),
etc.

40-296 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING H-21 BOOM SWING SPEED OR POWER IS LOW

H-21 BOOM SWING SPEED OR POWER IS LOW

Failure Boom swing speed or power is low
• Set working mode to power mode (P), and perform all troubleshooting with power mode
Related (P).
information • Check that the oil level in hydraulic tank is correct.
• Perform troubleshooting with the hydraulic oil temperature at 45 to 55 °C.

No. Cause Procedure, measuring location, criteria and remarks

Be ready with engine stopped, then perform troubleshooting with engine at high
idle.
0 MPa
Boom swing control pedal: NEUTRAL
{0 kg/cm2}
Malfunction of swing
1 PPC valve
PPC valve 2.94
outlet pres- (+0.49/-0.1)
sure Boom swing control pedal: Left swing and right swing MPa {30
(+5/-1)
kg/cm2}
Release remaining pressure from hydraulic tank and piping, and then perform trou-
bleshooting with engine stopped.
• Check if swing spool is stuck or seized with control valve body. (Spool
Malfunction of swing con-
2 should move smoothly.)
trol valve (spool)
• Remove swing spool from valve body, and check it for flaw and sticking of
dirt.
When restoring, be careful about the dirt, etc. to enter.
Malfunction of swing con- Pressure compensation valve of swing control valve may be defective. Check it.
3 trol valve (pressure com-
pensation valve)
Malfunction or defective Suction valve (head side) of swing control valve may malfunction or may have de-
sealing of swing control fective sealing. Check it.
4
valve (suction valve)
(swing RIGHT only)
Malfunction or defective Centralized safety valve and suction valve of control valve may malfunction or may
sealing of centralized have defective sealing. Check it.
5
safety valve and suction
valve
Be ready with engine stopped, then perform troubleshooting with engine at high
idle.
6 Defective swing cylinder Leakage of
swing cylin- Relief at the end of swing LEFT 10 cc/min
der

PC45MR-5, PC55MR-5 40-297

H-22 WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION 40 TROUBLESHOOTING

H-22 WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION

Failure Work equipment does not move in single operation
• Perform all troubleshooting with working mode to be set to power mode (P).
• Perform troubleshooting with the hydraulic oil temperature at 45 to 55 °C.
Related
REMARK
information
While the work equipment is used in single operation, if pump pressure remains at (approximate-
ly4 MPa {Approx. 40 kg/cm2 }), spool in the control valve probably stays at neutral position. (All the
oil from pump is drained to the tank through unload valve.)

No. Cause Procedure, measuring location, criteria and remarks

Be ready with engine stopped, then perform troubleshooting with engine at high
idle.
0 MPa
Work equipment control lever: NEUTRAL
{0 kg/cm2}
1 Malfunction of PPC valve PPC valve
2.94
outlet pres- (+0.49/-0.1)
sure Work equipment control lever: Operated MPa {30
(+5/-1)
kg/cm2}
Release remaining pressure from hydraulic tank and piping, and then perform trou-
bleshooting with engine stopped.
• Check if boom spool is stuck or seized with control valve body. (Spool
Malfunction of boom con-
2 should move smoothly.)
trol valve (spool)
• Remove boom spool from valve body, and check it for flaw and sticking of
dirt.
When restoring, be careful about the dirt, etc. to enter.
Release remaining pressure from hydraulic tank and piping, and then perform trou-
bleshooting with engine stopped.

Malfunction of bucket • Check for stuck or seized bucket spool in control valve body (spool should
4
control valve (spool) move smoothly).
• Remove bucket spool from valve body and check it for defects and dirt.
When restoring, be careful about the dirt, etc. to enter.
Release remaining pressure from hydraulic tank and piping, and then perform trou-
bleshooting with engine stopped.
• Check if swing spool is stuck or seized with control valve body. (Spool
Malfunction of swing con-
5 should move smoothly.)
trol valve (spool)
• Remove swing spool from valve body, and check it for flaw and sticking of
dirt.
When restoring, be careful about the dirt, etc. to enter.

40-298 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING H-23 HYDRAULIC DRIFT OF BOOM IS LARGE

H-23 HYDRAULIC DRIFT OF BOOM IS LARGE

Failure Hydraulic drift of boom is large.
• Set working mode to power mode (P), and perform all troubleshooting with power mode
Related
(P).
information
• Perform troubleshooting with the hydraulic oil temperature at 45 to 55 °C.

No. Cause Procedure, measuring location, criteria and remarks

Be ready with engine stopped, then perform troubleshooting with engine at high
idle.
1 Defective boom cylinder Leakage of
boom cylin- Boom RAISE relief 10 cc/min
der
• Check that pilot piston and puppet are seated on valve body in position.
(They should not be stuck halfway).
• Check if pilot piston and puppet are stuck or seized with lock valve body.
Malfunction of boom con- (They should move smoothly.)
2
trol valve (lock valve) • Remove pilot piston and puppet from valve body, and check them for flaw
and sticking of dirt.
• Check puppet spring for fatigue and deformation.
• When restoring, be careful about the dirt to enter.
Release remaining pressure from hydraulic tank and piping, and then perform trou-
bleshooting with engine stopped.
• Check if boom spool is stuck or seized with control valve body. (Spool
Malfunction of boom con-
3 should move smoothly.)
trol valve (spool)
• Remove boom spool from valve body, and check it for flaw and sticking of
dirt.
When restoring, be careful about the dirt, etc. to enter.
Be ready with engine stopped, then perform troubleshooting with engine at high
idle.
26.5 ±
Boom relief • Boom RAISE relief 0.98 MPa
Malfunction of centralized
4 pressure • Boom LOWER relief {270 ±
safety valve
10 kg/cm2}
If oil pressure does not become normal after adjustment, check safety valve for
malfunction (fatigued spring), internal defect (defective valve seat or entry of dirt),
etc.

PC45MR-5, PC55MR-5 40-299

H-24 HYDRAULIC DRIFT OF ARM IS LARGE 40 TROUBLESHOOTING

H-24 HYDRAULIC DRIFT OF ARM IS LARGE

Failure Hydraulic drift of arm is large.
• Set working mode to power mode (P), and perform all troubleshooting with power mode
Related
(P).
information
• Perform troubleshooting with the hydraulic oil temperature at 45 to 55 °C.

No. Cause Procedure, measuring location, criteria and remarks

Be ready with engine stopped, then perform troubleshooting with engine at high
idle.
1 Defective arm cylinder
Leakage of
Arm IN relief 10 cc/min
arm cylinder
Be ready with engine stopped, then perform troubleshooting with engine at high
idle.
26.5 ±
Arm relief 0.98 MPa
Arm IN relief
pressure {270 ±
10 kg/cm2}

Malfunction of arm con- REMARK

2 trol valve (suction valve) If only arm IN relief pressure is low among the work equipment relief pressures,
(IN side) suction valve may be defective. Check it.
• Check that check valve is seated on valve body in position (it is not stuck
halfway).
• Remove check valve from valve body, and check it for flaw and sticking of
dirt.
• Check spring for fatigue and deformation.
• When restoring, take care to prevent the dirt from entering.
Release remaining pressure from hydraulic tank and piping, and then perform trou-
bleshooting with engine stopped.

Malfunction of arm con- • Check for stuck or seized arm spool in control valve body (spool should
3
trol valve (spool) move smoothly).
• Remove arm spool from valve body and check for defects and dirt.
When restoring, be careful about the dirt, etc. to enter.
Be ready with engine stopped, then perform troubleshooting with engine at high
idle.
26.5 ±
Arm relief • Arm IN relief 0.98 MPa
Malfunction of centralized
4 pressure • Arm OUT relief {270 ±
safety valve
10 kg/cm2}
If oil pressure does not become normal after adjustment, check safety valve for
malfunction (fatigued spring), internal defect (defective valve seat or entry of dirt),
etc.

40-300 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING H-25 HYDRAULIC DRIFT OF BUCKET IS LARGE

H-25 HYDRAULIC DRIFT OF BUCKET IS LARGE

Failure Hydraulic drift of bucket is large.
Related • Perform all troubleshooting with working mode to be set to power mode (P).
information • Perform troubleshooting with the hydraulic oil temperature at 45 to 55 °C.

No. Cause Procedure, measuring location, criteria and remarks

Be ready with engine stopped, then perform troubleshooting with engine at high
idle.
1 Defective bucket cylinder Leakage of
bucket cylin- Bucket CURL relief 10 cc/min
der
Be ready with engine stopped, then perform troubleshooting with engine at high
idle.
26.5 ±
Bucket relief 0.98 MPa
Bucket CURL or DUMP relief
pressure {270 ±
10 kg/cm2}
If relief pressure is low, suction valve may be defective.
Malfunction of bucket • Remove check valve from valve body, and check it for flaw and sticking of
2 control valve (suction dirt.
valve) • Check spring for fatigue and deformation.
• When restoring, take care to prevent the dirt from entering.
• Check that check valve is seated on valve body in position (it is not stuck
halfway).
REMARK
You can replace suction valve with other one and check whether failure symp-
tom changes for judgment.
Release remaining pressure from hydraulic tank and piping, and then perform trou-
bleshooting with engine stopped.

PC45MR-5, PC55MR-5 40-301

H-26 HYDRAULIC DRIFT OF BLADE IS LARGE 40 TROUBLESHOOTING

H-26 HYDRAULIC DRIFT OF BLADE IS LARGE

Failure Hydraulic drift of blade is large (during blade RAISE or blade thrusting condition).
Related • Perform all troubleshooting with working mode to be set to power mode (P).
information • Perform troubleshooting with the hydraulic oil temperature at 45 to 55 °C.

No. Cause Procedure, measuring location, criteria and remarks

Be ready with engine stopped, then perform troubleshooting with engine at high
idle.
1 Defective blade cylinder Leakage of
blade cylin- Blade LOWER relief 10 cc/min
der
Be ready with engine stopped, then perform troubleshooting with engine at high
idle.
21.6(+0.98/-
Blade relief 0.49) MPa
Blade RAISE relief
pressure {220(+10/-5)
kg/cm2}
Malfunction of blade
2 RAISE (suction-safety • If blade RAISE relief pressure is low, suction valve may be defective.
valve) Check it.
• Check that check valve of suction safety valve is seated on valve body in
position (it is not stuck halfway).
REMARK
Since relief pressure of safety valve cannot be adjusted when it is installed on
the machine, replace safety valve assembly if it is found to be defective.
Release remaining pressure from hydraulic tank and piping, and then perform trou-
bleshooting with engine stopped.
• Check if the bucket spool is stuck or seized with control valve body. (Spool
Malfunction of blade con- should move smoothly.)
3
trol valve (spool)
• Remove the blade spool from valve body, and check it for flaw and sticking
of dirt.
• When restoring, be careful about the dirt to enter.
Be ready with engine stopped, then perform troubleshooting with engine at high
idle.
21.6(+0.98/-
Blade relief 0.49) MPa
Blade LOWER relief
pressure {220(+10/-5)
kg/cm2}
Malfunction of blade • If only blade LOWER relief pressure is low between swing and blade
4 LOWER (suction safety LOWER relief pressure, suction valve may be defective. Check it.
valve)
• Check that check valve of suction valve is seated on valve body in position
(it is not stuck halfway).
• Remove check valve from valve body, and check it for flaw and sticking of
dirt.
• Check spring for fatigue and deformation.
• When restoring, be careful about the dirt to enter.

40-302 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING H-26 HYDRAULIC DRIFT OF BLADE IS LARGE

No. Cause Procedure, measuring location, criteria and remarks

Be ready with engine stopped, then perform troubleshooting with engine at high
idle.
21.6
(+0.98/-0.49
Blade relief
Malfunction of centralized Blade LOWER relief ) MPa {220
5 pressure
safety valve (+10/-5)
kg/cm2}
If oil pressure does not become normal after adjustment, check safety valve for
malfunction (fatigued spring), internal defect (defective valve seat or entry of dirt),
etc.
6 Defective swivel joint If no failure is found by above checks, seal of swivel joint may be defective.

PC45MR-5, PC55MR-5 40-303

H-27 TIME LAG OF WORK EQUIPMENT IS LARGE 40 TROUBLESHOOTING

H-27 TIME LAG OF WORK EQUIPMENT IS LARGE

Failure Time lag of work equipment is large.
• Set working mode to power mode (P), and perform all troubleshooting with power mode
Related (P).
information • Check that oil level in hydraulic tank is normal.
• Perform troubleshooting with the hydraulic oil temperature at 45 to 55 °C.

No. Cause Procedure, measuring location, criteria and remarks

Check relief pressure of each work equipment. If only relief pressure at boom head
side is abnormal, suction valve of boom control valve may malfunction. Check it.
Malfunction of boom con-
1 REMARK
trol valve (suction valve)
You can replace it with other suction valve and check whether failure symptom
changes for judgment.
Check relief pressure of each work equipment. If only arm relief pressure is abnor-
mal, suction valve of arm control valve may malfunction.
Malfunction of arm con-
2 REMARK
trol valve (suction valve)
You can replace it with other suction valve and check whether failure symptom
changes for judgment.
Check relief pressure of each work equipment. If only bucket relief pressure is ab-
Malfunction of bucket normal, suction valve of bucket control valve may malfunction.
3 control valve (suction REMARK
valve) You can replace it with other suction valve and check whether failure symptom
changes for judgment.
Check relief pressure of each work equipment. If only blade relief pressure is ab-
Malfunction of blade con- normal, suction valve and suction safety valve of blade control valve may malfunc-
trol valve tion.
4 (Suction safety valve) REMARK
(Suction valve) You can replace it with other suction valve and check whether failure symptom
changes for judgment.
Malfunction of centralized Check relief pressure of each work equipment. If relief pressure of all work equip-
5
safety valve ment other than blade RAISE is unusual, centralized safety valve may malfunction.

Malfunction of rebuilt Release remaining pressure from hydraulic tank and piping, and then perform trou-
6 check valve in boom bleshooting with engine stopped.
spool Check the surface and hole part of spool for flaw and sticking of dirt.
Release remaining pressure from hydraulic tank and piping, and then perform trou-
Malfunction of rebuilt bleshooting with engine stopped.
7
check valve in arm spool
Check the surface and hole part of spool for flaw and sticking of dirt.

40-304 PC45MR-5, PC55MR-5

H-28 IN COMBINED OPERATION OF WORK EQUIPMENT, EQUIP-
40 TROUBLESHOOTING MENT HAVING HEAVIER LOAD MOVES SLOWER

H-28 IN COMBINED OPERATION OF WORK EQUIPMENT, EQUIPMENT

HAVING HEAVIER LOAD MOVES SLOWER
Failure In combined operation of work equipment, equipment having heavier load moves slower.
• Set working mode to power mode (P), and perform all troubleshooting with power mode
Related
(P).
information
• Perform troubleshooting with the hydraulic oil temperature at 45 to 55 °C.

No. Cause Procedure, measuring location, criteria and remarks

Pressure compensation valve of control valve with smaller load may be defective.
Arm pres-
Combination of combined
Side with larger load: sure com-
operations: Boom RAISE
Boom pensation
+ Arm IN
valve
Boom pres-
Combination of combined
sure com-
operations: Boom RAISE Side with larger load: Arm
pensation
+ Arm OUT
valve
Malfunction of control
valve (pressure compen- Malfunction Combination of combined
Bucket pres-
1
sation valve) with smaller of pressure operations: Boom RAISE
Side with larger load: sure com-
load compensa- Boom pensation
+ Bucket CURL
tion valve valve
Bucket pres-
Combination of combined
sure com-
operations: Arm OUT + Side with larger load: Arm
pensation
Bucket CURL
valve
Boom pres-
Combination of combined
sure com-
operations: Boom LOWER Side with larger load: Arm
pensation
+ Arm OUT
valve

PC45MR-5, PC55MR-5 40-305

H-29 MACHINE DOES NOT TRAVEL STRAIGHT 40 TROUBLESHOOTING

H-29 MACHINE DOES NOT TRAVEL STRAIGHT

Failure Machine does not travel straight.
• Set working mode to power mode (P), and perform all troubleshooting with power mode
(P).
Related
• Check that oil level in hydraulic tank is normal.
information
• Perform troubleshooting with the hydraulic oil temperature at 45 to 55 °C.
• Travel PPC pressure can be checked on the monitor as well. Code: (07101)

No. Cause Procedure, measuring location, criteria and remarks

Defective center swivel Check whether the turn direction changes if the right and left hoses are switched
1
joint between the swivel joint and travel motor.
Be ready with engine stopped, then perform troubleshooting with engine at high
idle.
0 MPa
R.H. travel lever: NEUTRAL
R.H. travel {0 kg/cm2}
PPC valve 2.94(+0.49/-
outlet pres- 0.1) MPa
Malfunction of R.H. travel sure R.H. travel lever: FORWARD/REVERSE
2 {30(+5/-1)
PPC valve kg/cm2}
Difference
between Within.
R.H. and 0.4 MPa
Travel lever: FORWARD/REVERSE
L.H. of PPC {Within.
valve outlet 4 kg/cm2}
pressure
Be ready with engine stopped, then perform troubleshooting with engine at high
idle.
0 MPa
L.H. travel lever: NEUTRAL
{0 kg/cm2}
L.H. PPC
valve outlet 2.94(+0.49/-
pressure 0.1) MPa
Malfunction of L.H. travel L.H. travel lever: FORWARD/REVERSE
3 {30(+5/-1)
PPC valve kg/cm2}
Difference
between Within.
R.H. and 0.4 MPa
Travel lever: FORWARD/REVERSE
L.H. of PPC {Within.
valve outlet 4 kg/cm2}
pressure
Release remaining pressure from hydraulic tank and piping, and then perform trou-
bleshooting with engine stopped.
Malfunction of travel
4 • Check travel Junction valve for stick (spool should move smoothly).
Junction valve (spool)
• Remove spool from valve body, and check it for flaw and sticking of dirt.
When restoring, be careful about the dirt, etc. to enter.

40-306 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING H-29 MACHINE DOES NOT TRAVEL STRAIGHT

No. Cause Procedure, measuring location, criteria and remarks

Release remaining pressure from hydraulic tank and piping, and then perform trou-
bleshooting with engine stopped.
• Check for stuck or seized spool with merge-divider valve body (spool
Malfunction of merge-di- should move smoothly).
5
vider valve (spool)
• Remove merge-divider spool from valve body, and check it for flaw and
sticking of dirt.
• When restoring, be careful about the dirt, etc. to enter.
Be ready with engine stopped, then perform troubleshooting with engine at high
idle.
Malfunction of unload 2.9±0.49
6
valve Unload MPa
All control levers in NEUTRAL
pressure {30±5
kg/cm2}
7 Malfunction of logic valve Logic valve may malfunction. Check it.
Release remaining pressure from hydraulic tank and piping, and then perform trou-
bleshooting with engine stopped.
• Check if travel spool is stuck or seized with control valve body. (Spool
Malfunction of R.H. travel should move smoothly.)
8
control valve (spool)
• Remove travel spool from valve body, and check it for flaw and sticking of
dirt.
• When restoring, be careful about the dirt to enter.
Release remaining pressure from hydraulic tank and piping, and then perform trou-
bleshooting with engine stopped.
Malfunction of L.H. travel • Check if travel spool is stuck or seized with control valve body. (Spool
9
control valve (spool) should move smoothly.)
• Remove travel spool from valve body, and check it for flaw and sticking of
dirt.
Travel motor may have an internal defect. Check it. (You can exchange right and
10 Defective travel motor left travel motors and final drive assemblies, and check whether the direction of
travel deviation changes for judgment.)
Check for unusual noise, unusual heat, and metallic powders in drained oil to make
11 Defective final drive
judgment.
Defective adjustment of See TESTING AND ADJUSTING, “TEST AND ADJUST TRAVEL DEVIATION” to
12 travel deviation adjust- adjust.
ment plug

PC45MR-5, PC55MR-5 40-307

H-30 MACHINE DOES NOT MOVE OFF STRAIGHT 40 TROUBLESHOOTING

H-30 MACHINE DOES NOT MOVE OFF STRAIGHT

Failure Machine deviates when moving off.
• Set working mode to power mode (P), and perform all troubleshooting with power mode
(P).
Related
• Check that the oil level in hydraulic tank is correct.
information
• Perform troubleshooting with the hydraulic oil temperature at 45 to 55 °C.
• Travel PPC pressure can be checked on the monitor as well. Code: 07101)

No. Cause Procedure, measuring location, criteria and remarks

Defective travel motor Counter balance valve and check valve of travel motor may malfunction. Check it.
1 (counterbalance valve (You can exchange them between forward and reverse or right and left of the same
and check valve) motor, and check whether failure symptom changes for judgment.)
Be ready with engine stopped, then perform troubleshooting with engine at high
idle.
0 MPa
R.H. travel lever: NEUTRAL
R.H. travel {0 kg/cm2}
PPC valve 2.94(+0.49/-
outlet pres- 0.1) MPa
Malfunction of R.H. travel sure R.H. travel lever: FORWARD/REVERSE
2 {30(+5/-1)
PPC valve kg/cm2}
Difference
between Within.
R.H. and 0.4 MPa
Travel lever: FORWARD/REVERSE
L.H. of PPC {Within.
valve outlet 4 kg/cm2}
pressure
Be ready with engine stopped, then perform troubleshooting with engine at high
idle.
0 MPa
L.H. travel lever: NEUTRAL
{0 kg/cm2}
L.H. PPC
valve outlet 2.94(+0.49/-
pressure 0.1) MPa
Malfunction of L.H. travel L.H. travel lever: FORWARD/REVERSE
3 {30(+5/-1)
PPC valve kg/cm2}
Difference
between Within.
R.H. and 0.4 MPa
Travel lever: FORWARD/REVERSE
L.H. of PPC {Within.
valve outlet 4 kg/cm2}
pressure
Defective R.H. travel mo- If R.H. track does not move in relief pressure state when operating R.H. travel off
4
tor (parking brake) ground, travel parking brake may malfunction.
Defective L.H. travel mo- If L.H. track does not move in relief pressure state when operating L.H. travel off
5
tor (parking brake) ground, travel parking brake may malfunction.

40-308 PC45MR-5, PC55MR-5

H-31 MACHINE IS NOT STEERED WELL OR STEERING POWER IS
40 TROUBLESHOOTING LOW

H-31 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW

Failure Machine is not steered well or steering power is low.
• Set working mode to power mode (P), and perform all troubleshooting with power mode
Related (P).
information • Perform troubleshooting with the hydraulic oil temperature at 45 to 55 °C.
• Travel PPC pressure can be checked on the monitor as well. Code: (07101)

No. Cause Procedure, measuring location, criteria and remarks

Be ready with engine stopped, then perform troubleshooting with engine at high
idle.
0 MPa
R.H. travel lever: NEUTRAL
Malfunction of R.H. travel R.H. travel {0 kg/cm2}
1
PPC valve PPC valve 2.94(+0.49/-
outlet pres- 0.1) MPa
sure R.H. travel lever: FORWARD/REVERSE
{30(+5/-1)
kg/cm2}
Be ready with engine stopped, then perform troubleshooting with engine at high
idle.
0 MPa
L.H. travel lever: NEUTRAL
Malfunction of L.H. travel {0 kg/cm2}
2 L.H. PPC
PPC valve
valve outlet 2.94(+0.49/-
pressure 0.1) MPa
L.H. travel lever: FORWARD/REVERSE
{30(+5/-1)
kg/cm2}
3 Malfunction of logic valve Logic valve may malfunction. Check it.
Release remaining pressure from hydraulic tank and piping, and then perform trou-
bleshooting with engine stopped.
Malfunction of travel
4 • Check travel Junction valve for stick (spool should move smoothly).
Junction valve (spool)
• Remove spool from valve body, and check it for flaw and sticking of dirt.
When restoring, be careful about the dirt, etc. to enter.
Release remaining pressure from hydraulic tank and piping, and then perform trou-
bleshooting with engine stopped.

Malfunction of merge-di- • Check for stuck or seized main spool in merge-divider valve body (spool
5
vider main spool should move smoothly).
• Remove main spool from valve body and check it for defects and dirt.
When restoring, be careful about the dirt, etc. to enter.
Release remaining pressure from hydraulic tank and piping, and then perform trou-
bleshooting with engine stopped.
• Check if travel spool is stuck or seized with control valve body. (Spool
Malfunction of R.H. travel should move smoothly.)
6
control valve (spool)
• Remove travel spool from valve body, and check it for flaw and sticking of
dirt.
• When restoring, be careful about the dirt to enter.

PC45MR-5, PC55MR-5 40-309

H-31 MACHINE IS NOT STEERED WELL OR STEERING POWER IS
LOW 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

Release remaining pressure from hydraulic tank and piping, and then perform trou-
bleshooting with engine stopped.
Malfunction of L.H. travel • Check if travel spool is stuck or seized with control valve body. (Spool
7
control valve (spool) should move smoothly.)
• Remove travel spool from valve body, and check it for flaw and sticking of
dirt.
Be ready with engine stopped, then perform troubleshooting with engine at high
idle.
Malfunction of travel con-
8 trol valve (pressure com- 26.5±0.98
pensation valve) (R.H.) Travel relief MPa
R.H. travel FORWARD hydraulic relief
pressure {270±10
kg/cm2}
Be ready with engine stopped, then perform troubleshooting with engine at high
idle.
Malfunction of travel con-
9 trol valve (pressure com- 26.5±0.98
pensation valve) (L.H.) Travel relief MPa
L.H. travel FORWARD hydraulic relief
pressure {270±10
kg/cm2}
Defective operation of Even after the relief valve is adjusted, if the relief pressure is low at only 1 port,
10 travel control valve (suc- suction valve may malfunction. Check the check valve for damage and spring for
tion valve) fatigue.
Defective center swivel Check whether the turn direction changes if the right and left hoses are switched
11
joint between the swivel joint and travel motor.
In the check on cause (6) and (8), if "Right Travel" is abnormal on both forward and
Defective R.H. travel mo- reverse, or "Left Travel" is abnormal on both forward and reverse, safety valve may
12
tor (safety valve) malfunction. Exchange the safety valves of right and left travel motor and check
whether the phenomenon changes.
In the check on cause (7) and (9), if "Left Travel" is abnormal on both forward and
Defective L.H. travel mo-
13 reverse, safety valve may malfunction. Exchange the safety valves of right and left
tor (safety valve)
travel motor and check whether the phenomenon changes.
In the check on cause (6) and (8), if the pressure compensation valve is normal,
Defective R.H. travel mo-
14 check valve may malfunction. Exchange the safety valves of right and left travel
tor (check valve)
motor and check whether the phenomenon changes.
In the check on cause (7) and (9), if the pressure compensation valve is normal,
Defective L.H. travel mo-
15 check valve may malfunction. Exchange the forward and reverse check valves of
tor (check valve)
the same motor and check whether the phenomenon changes.
Defective travel motor Counter balance valve and check valve of travel motor may malfunction. Check it.
16 (counterbalance valve (You can exchange them between forward and reverse or right and left of the same
and check valve) motor, and check whether failure symptom changes for judgment.)

40-310 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING H-32 TRAVEL SPEED IS LOW

H-32 TRAVEL SPEED IS LOW

Failure Travel speed is slow.
• Set working mode to power mode (P), and perform all troubleshooting with power mode
(P).
Related • Check that the oil level in hydraulic tank is correct.
information • Perform troubleshooting with the hydraulic oil temperature at 45 to 55 °C.
• Check that machine has no travel deviation.
• Travel PPC pressure can be checked on the monitor as well. Code: 07101)

No. Cause Procedure, measuring location, criteria and remarks

Malfunction of merge-di- • Check for stuck or seized main spool in merge-divider valve body (spool
3
vider main spool should move smoothly).
• Remove main spool from valve body and check it for defects and dirt.
When restoring, be careful about the dirt, etc. to enter.
Be ready with engine stopped, then perform troubleshooting with engine at high
idle.
Malfunction of unload 2.9±0.49
4
valve Unload MPa
All control levers in NEUTRAL
pressure {30±5
kg/cm2}

PC45MR-5, PC55MR-5 40-311

H-32 TRAVEL SPEED IS LOW 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

Travel motor may have an internal defect. Check it. (You can exchange right and
5 Defective travel motor left travel motors and final drive assemblies, and check whether the direction of
travel deviation changes for judgment.)
Check for unusual noise, unusual heat, and metallic powders in drained oil to make
6 Defective final drive
judgment.
• Check that track shoe tension is adjusted equally on right and left.
7 Defective undercarriage • Check front idler and roller, etc. for defective rotation, deformation, dam-
age.
8 Malfunction of logic valve Logic valve may malfunction. Check it.
Release remaining pressure from hydraulic tank and piping, and then perform trou-
bleshooting with engine stopped.
Malfunction of travel
9 • Check travel Junction valve for stick (spool should move smoothly).
Junction valve (spool)
• Remove spool from valve body, and check it for flaw and sticking of dirt.
When restoring, be careful about the dirt, etc. to enter.
Be ready with engine stopped, then perform troubleshooting with engine at high
idle.
Malfunction of travel con-
10 trol valve (pressure com- 26.5±0.98
pensation valve) (R.H.) Travel relief MPa
R.H. travel FORWARD hydraulic relief
pressure {270±10
kg/cm2}
Be ready with engine stopped, then perform troubleshooting with engine at high
idle.
Malfunction of travel con-
11 trol valve (pressure com- 26.5±0.98
pensation valve) (L.H.) Travel relief MPa
L.H. travel FORWARD hydraulic relief
pressure {270±10
kg/cm2}
Be ready with engine stopped, then perform troubleshooting with engine at high
idle.
Improper adjustment or
12 malfunction of main relief 26.5 ±
valve Main relief 0.98 MPa
Travel hydraulic relief
pressure {270 ±
10 kg/cm2}

40-312 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING H-33 BOTH SIDES OF CRAWLERS DO NOT MOVE

H-33 BOTH SIDES OF CRAWLERS DO NOT MOVE

Failure Travel do not operate (both sides of tracks).
• Set working mode to power mode (P), and perform all troubleshooting with power mode
(P).
• Check that the oil level in hydraulic tank is correct.
• Perform troubleshooting with the hydraulic oil temperature at 45 to 55 °C.
• Travel PPC pressure can be checked on the monitor as well. Code: 07101)
REMARK
• Prepare PPC circuit check valves of A to D as shown in the figure below, and take out
Related signal voltage for switching merge valve from travel PPC pressure.
information • If back flow prevention function of check valves of A to D are damaged, travel may not
operate.
• (Ex.) When back flow prevention function of A is damaged
• Operation by which travel operates normally: (L.H. track forward), (L.H. track forward
and R.H. track forward), (L.H. track forward and R.H. track reverse)
• Operation by which travel may not operate: (L.H. track reverse), (R.H. track forward),
(R.H. track reverse), (L.H. track reverse and R.H. track forward), (L.H. track reverse
and R.H. track reverse)

No. Cause Procedure, measuring location, criteria and remarks

Defective check valve in If PPC circuit pressure is normal for only 1 circuit among left travel (forward and re-
travel circuit verse) and right travel (forward and reverse), the PPC circuit check valve in normal
1
(For merge-divider valve circuit may be defective. Check it.
operating pressure)

Related diagram between defective PPC circuit check valve and “TRAVEL DOES
NOT OPERATE”

PC45MR-5, PC55MR-5 40-313

H-34 ONE OF TRACKS DOES NOT RUN 40 TROUBLESHOOTING

H-34 ONE OF TRACKS DOES NOT RUN

Failure One of tracks does not run.
• Perform all troubleshooting with working mode to be set to power mode (P).
Related • Check that oil level in hydraulic tank is normal.
information • Perform troubleshooting with the hydraulic oil temperature at 45 to 55 °C.
• Travel PPC pressure can be checked on the monitor as well. Code: (07101)

No. Cause Procedure, measuring location, criteria and remarks

Be ready with engine stopped, then perform troubleshooting with engine at high
idle.
0 MPa
R.H. travel lever: NEUTRAL
R.H. travel {0 kg/cm2}
PPC valve 2.94(+0.49/-
outlet pres- 0.1) MPa
Malfunction of R.H. travel sure R.H. travel lever: FORWARD/REVERSE
1 {30(+5/-1)
PPC valve kg/cm2}
Difference
between Within.
R.H. and 0.4 MPa
Travel lever: FORWARD/REVERSE
L.H. of PPC {Within.
valve outlet 4 kg/cm2}
pressure
Be ready with engine stopped, then perform troubleshooting with engine at high
idle.
0 MPa
L.H. travel lever: NEUTRAL
{0 kg/cm2}
L.H. PPC
valve outlet 2.94(+0.49/-
pressure 0.1) MPa
Malfunction of L.H. travel L.H. travel lever: FORWARD/REVERSE
2 {30(+5/-1)
PPC valve kg/cm2}
Difference
between Within.
R.H. and 0.4 MPa
Travel lever: FORWARD/REVERSE
L.H. of PPC {Within.
valve outlet 4 kg/cm2}
pressure
If no failure is found by check on R.H. travel PPC valve, and one track does not run
Malfunction of R.H. travel
3 when travel control lever is operated with pump pressure at approx. 4 MPa, check
control valve (spool)
whether spool is stuck near neutral position.
If no failure is found by check on L.H. travel PPC valve, and one track does not run
Malfunction of L.H. travel
4 when travel control lever is operated with pump pressure at approx. 4 MPa, check
control valve (spool)
whether spool is stuck near neutral position.
Malfunction of R.H. travel If one track does not run due to low pump pressure, when Right Travel is operated,
5 control valve (suction check suction valve.
valve)
Malfunction of L.H. travel If one track does not run due to low pump pressure, when Left Travel is operated,
6 control valve (suction check suction valve.
valve)
Travel motor may have an internal defect. Check it. (You can exchange right and
7 Defective travel motor left travel motors and final drive assemblies, and check whether the direction of
travel deviation changes for judgment.)

40-314 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING H-34 ONE OF TRACKS DOES NOT RUN

No. Cause Procedure, measuring location, criteria and remarks

Check for unusual noise, unusual heat, and metallic powders in drained oil to make
8 Defective final drive
judgment.
Defective travel motor Counter balance valve and check valve of travel motor may malfunction. Check it.
9 (counterbalance valve (You can exchange them between forward and reverse or right and left of the same
and check valve) motor, and check whether failure symptom changes for judgment.)

PC45MR-5, PC55MR-5 40-315

H-35 TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS
TOO SLOW OR FAST 40 TROUBLESHOOTING

H-35 TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO

SLOW OR FAST
Failure Travel speed does not change, or travel speed is too slow or fast.
• Perform all troubleshooting with working mode to be set to power mode (P).
• Check that oil level in hydraulic tank is normal.

Related • Perform troubleshooting with the hydraulic oil temperature at 45 to 55 °C.

information • If failure codes are displayed, troubleshoot displayed failure codes first. (DW43KA,
DW43KB, and DW43KY)
• Travel speed selector solenoid (ON/OFF) can also be checked on monitor. (Monitoring
code: 02300)

No. Cause Procedure, measuring location, criteria and remarks

Be ready with engine stopped, then perform troubleshooting with engine at high
idle.
0 MPa
Travel speed: Lo Travel lever: NEUTRAL
Malfunction of travel {0 kg/cm2}
1 Solenoid
speed solenoid valve
valve outlet 2.94(+0.49/-
pressure 0.1) MPa
Travel speed: Hi Travel lever: Fine control
{30(+5/-1)
kg/cm2}
Defective travel motor If no failure is found by checks on preceding item, speed switching part of travel
2
(speed switching section) motor may malfunction.

40-316 PC45MR-5, PC55MR-5

H-36 UPPER STRUCTURE DOES NOT SWING BOTH TO THE RIGHT
40 TROUBLESHOOTING AND LEFT

H-36 UPPER STRUCTURE DOES NOT SWING BOTH TO THE RIGHT AND
LEFT
Failure Upper structure does not swing both to the right and left.
• Set working mode to power mode (P), and perform all troubleshooting with power mode
(P).
Related • Check that the oil level in hydraulic tank is correct.
information • Perform troubleshooting with the hydraulic oil temperature at 45 to 55 °C.
• If blade does not operate, perform troubleshooting for “SWING AND BLADE DO NOT OP-
ERATE” in H mode first.

No. Cause Procedure, measuring location, criteria and remarks

Be ready with engine stopped, then perform troubleshooting with engine at high
idle.
0 MPa
L.H. work equipment control lever: In NEUTRAL
Malfunction of swing {0 kg/cm2}
1 Swing PPC
PPC valve
valve outlet 2.94(+0.49/-
pressure L.H. work equipment control lever: In swing RIGHT/ 0.1) MPa
LEFT direction {30(+5/-1)
kg/cm2}
Be ready with engine stopped, then perform troubleshooting with engine at high
idle.
Swing motor 2.94
parking (+0.49/-0.1)
Malfunction of swing mo- L.H. work equipment control lever: Operate arm IN di-
2 brake re- MPa {30
tor (swing parking brake) rection or swing RIGHT/LEFT direction
lease pres- (+5/-1)
sure kg/cm2}
If no failure is found by preceding checks, the swing parking brake may malfunc-
tion. Check it.
Be ready with engine stopped, then perform troubleshooting with engine at high
idle.
Swing relief 19.6±0.98
Malfunction of swing mo- pressure L.H. work equipment control lever: Swing LEFT relief, MPa
3
tor (safety valve) (pump pres- swing RIGHT relief {200±10
sure) kg/cm2}
If the relief pressures are same at right and left swing and lower than specified val-
ue, sealing of safety valve may be defective.
Be ready with engine stopped, then perform troubleshooting with engine at high
idle.
2.94
Swing PPC (+0.49/-0.1)
Malfunction of swing con- L.H. work equipment control lever: Operate swing
4 circuit pres- MPa {30
trol valve (spool) RIGHT/LEFT direction
sure (+5/-1)
kg/cm2}
If no failure is found by preceding checks, the spool of swing control valve may
malfunction. Check it.

PC45MR-5, PC55MR-5 40-317

H-36 UPPER STRUCTURE DOES NOT SWING BOTH TO THE RIGHT
AND LEFT 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

Be ready with engine stopped, then perform troubleshooting with engine at high
idle.
Swing motor 2.94
Malfunction of check
parking (+0.49/-0.1)
valve in the circuit for L.H. work equipment control lever: Operate arm IN di-
5 brake re- MPa {30
swing parking brake re- rection or swing RIGHT/LEFT direction
lease pres- (+5/-1)
leasing pressure
sure kg/cm2}
If there is a defective hydraulic circuit, the check valve of PPC circuit at swing
RIGHT/LEFT and arm IN side may be defective. Check it.
Defective swing machi- Check for unusual noise, unusual heat, and metallic powders in drained oil to make
6
nery judgment.
Performance deterioration, malfunction, and internal defect of the gear pump may
7 Defective gear pump
be occurred. Check it.
Be ready with engine stopped, then perform troubleshooting with engine at high
idle.
Incorrect adjustment or
malfunction of relief valve Swing and 21.6
8 (+0.98/-0.49
for Swing and blade blade pump
pump Blade LOWER relief ) MPa {220
relief pres-
(+10/-5)
sure
kg/cm2}
If no failure is found by preceding checks, internal defect of the swing motor is sus-
9 Defective swing motor
pected. Check it.

40-318 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING H-37 SWINGS ONLY IN ONE DIRECTION

H-37 SWINGS ONLY IN ONE DIRECTION

Failure Upper structure swings either to the right or to the left.
• Set working mode to power mode (P), and perform all troubleshooting with power mode
(P).
• Check that the oil level in hydraulic tank is correct.
Related
• Perform troubleshooting with the hydraulic oil temperature at 45 to 55 °C.
information
• Swing PPC pressure can be checked with monitoring function. (Code: 09000)
• If blade does not operate, perform troubleshooting for “SWING AND BLADE DO NOT OP-
ERATE” in H mode first.

No. Cause Procedure, measuring location, criteria and remarks

Be ready with engine stopped, then perform troubleshooting with engine at high
idle.
0 MPa
L.H. work equipment control lever: In NEUTRAL
Malfunction of swing {0 kg/cm2}
1 Swing PPC
PPC valve
valve outlet 2.94(+0.49/-
pressure L.H. work equipment control lever: In swing RIGHT/ 0.1) MPa
LEFT direction {30(+5/-1)
kg/cm2}
Be ready with engine stopped, then perform troubleshooting with engine at high
idle.
2.94
Swing PPC (+0.49/-0.1)
Malfunction of swing con- L.H. work equipment control lever: Operate swing
2 circuit pres- MPa {30
trol valve (spool) RIGHT/LEFT direction
sure (+5/-1)
kg/cm2}
If no failure is found by preceding checks, the spool of swing control valve may
malfunction. Check it.
Replace the suction valves of R.H. and L.H. swing motor, and check whether failure
symptom changes to make judgment. When taking out the valve, check it for stick-
ing and flaw.
Be ready with engine stopped, then perform troubleshooting with engine at high
Defective seal of swing
3 idle.
motor (suction valve)
Swing relief 19.6±0.98
pressure L.H. work equipment control lever: Swing LEFT relief, MPa
(pump pres- swing RIGHT relief {200±10
sure) kg/cm2}
Be ready with engine stopped, then perform troubleshooting with engine at high
idle.
Defective sealing of
4 swing motor (check Swing relief 19.6±0.98
valve) pressure L.H. work equipment control lever: Swing LEFT relief, MPa
(pump pres- swing RIGHT relief {200±10
sure) kg/cm2}
Malfunction of load check Load check valve in the control valve may be defective. Check it.
5 valve in the spool of con-
trol valve

PC45MR-5, PC55MR-5 40-319

H-37 SWINGS ONLY IN ONE DIRECTION 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

40-320 PC45MR-5, PC55MR-5

H-38 SWING ACCELERATION OR SWING SPEED IS LOW IN BOTH
40 TROUBLESHOOTING DIRECTIONS (RIGHT AND LEFT)

H-38 SWING ACCELERATION OR SWING SPEED IS LOW IN BOTH DIREC-

TIONS (RIGHT AND LEFT)
Failure Swing acceleration or swing speed is low in both directions of right and left.
• Set working mode to power mode (P), and perform all troubleshooting with power mode
(P).
Related • Check that the oil level in hydraulic tank is correct.
information • Perform troubleshooting with the hydraulic oil temperature at 45 to 55 °C.
• If blade speed is slow, perform troubleshooting for “SWING AND BLADE SPEED IS LOW
OR POWER IS LOW” in H mode first.

No. Cause Procedure, measuring location, criteria and remarks

Be ready with engine stopped, then perform troubleshooting with engine at high
idle.
Swing relief 19.6±0.98
Malfunction of swing mo- pressure L.H. work equipment control lever: Swing LEFT relief, MPa
1
tor (safety valve) (pump pres- swing RIGHT relief {200±10
sure) kg/cm2}
If normal pressure is not obtained after adjustment, sealing of safety valve may be
defective.
Be ready with engine stopped, then perform troubleshooting with engine at high
idle.
Swing motor 2.94
Malfunction of swing mo- parking (+0.49/-0.1)
2 L.H. work equipment control lever: Operate arm IN di-
tor parking brake brake re- MPa {30
rection or swing RIGHT/LEFT direction
lease pres- (+5/-1)
sure kg/cm2}
If no failure is found by preceding checks, the brake may malfunction. Check it.
Defective swing machi- Check for unusual noise, unusual heat, and metallic powders in drained oil to make
3
nery judgment.
Be ready with engine stopped, then perform troubleshooting with engine at high
idle.
0 MPa
L.H. work equipment control lever: In NEUTRAL
Malfunction of swing {0 kg/cm2}
4 Swing PPC
PPC valve
valve outlet 2.94(+0.49/-
pressure L.H. work equipment control lever: In swing RIGHT/ 0.1) MPa
LEFT direction {30(+5/-1)
kg/cm2}
Be ready with engine stopped, then perform troubleshooting with engine at high
idle.
2.94
Swing PPC (+0.49/-0.1)
Malfunction of swing con- L.H. work equipment control lever: Operate swing
5 circuit pres- MPa {30
trol valve (spool) RIGHT/LEFT direction
sure (+5/-1)
kg/cm2}
If no failure is found by preceding checks, the spool of swing control valve may
malfunction. Check it.

PC45MR-5, PC55MR-5 40-321

H-38 SWING ACCELERATION OR SWING SPEED IS LOW IN BOTH
DIRECTIONS (RIGHT AND LEFT) 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

Be ready with engine stopped, then perform troubleshooting with engine at high
idle.
Incorrect adjustment or
malfunction of relief valve Swing and 21.6
6 (+0.98/-0.49
for Swing and blade blade pump
pump Blade LOWER relief ) MPa {220
relief pres-
(+10/-5)
sure
kg/cm2}
Clogging of swing PPC Check for unusual noise, unusual heat, and metallic powders in drained oil to make
7 line throttle, slow return judgment.
valve
If no failure is found by preceding checks, internal defect of the swing motor is sus-
8 Defective swing motor
pected. Check it.

40-322 PC45MR-5, PC55MR-5

H-39 SWING ACCELERATION PERFORMANCE IS POOR OR SWING
40 TROUBLESHOOTING SPEED IS SLOW IN ONLY ONE DIRECTION

H-39 SWING ACCELERATION PERFORMANCE IS POOR OR SWING

SPEED IS SLOW IN ONLY ONE DIRECTION
Failure Swing acceleration performance is poor or swing speed is slow in only one direction.
• Set working mode to power mode (P), and perform all troubleshooting with power mode
(P).
• Check that the oil level in hydraulic tank is correct.
Related
• Perform troubleshooting with the hydraulic oil temperature at 45 to 55 °C.
information
• Swing PPC pressure can be checked with monitoring function. (Code: 09000)
• If blade speed is slow, perform troubleshooting for “SWING AND BLADE SPEED IS LOW
OR POWER IS LOW” in H mode first.

No. Cause Procedure, measuring location, criteria and remarks

PC45MR-5, PC55MR-5 40-323

H-40 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT
STOPS SWINGING (BOTH RIGHT AND LEFT) 40 TROUBLESHOOTING

H-40 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS

SWINGING (BOTH RIGHT AND LEFT)
Failure Upper structure overruns excessively when it stops swinging (both right and left).
• Perform all troubleshooting with working mode to be set to power mode (P).
Related
• Check that oil level in hydraulic tank is normal.
information
• Perform troubleshooting with the hydraulic oil temperature at 45 to 55 °C.

No. Cause Procedure, measuring location, criteria and remarks

40-324 PC45MR-5, PC55MR-5

H-41 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT
40 TROUBLESHOOTING STOPS SWINGING (ONLY ONE DIRECTION EITHER RIGHT OR LEFT)

H-41 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS

SWINGING (ONLY ONE DIRECTION EITHER RIGHT OR LEFT)
Failure Upper structure overruns excessively when it stops swinging (either right or left).
• Perform all troubleshooting with working mode set in power mode (P).
Related • Check that oil level in hydraulic tank is normal.
information • Perform troubleshooting with the hydraulic oil temperature at 45 to 55 °C.
• Swing PPC pressure can be checked with monitoring function. (Code: 09000)

No. Cause Procedure, measuring location, criteria and remarks

Be ready with engine stopped, then perform troubleshooting with engine at high
idle.
0 MPa
L.H. work equipment control lever: In NEUTRAL
Malfunction of swing {0 kg/cm2}
1 Swing PPC
PPC valve
valve outlet 2.94(+0.49/-
pressure L.H. work equipment control lever: In swing RIGHT/ 0.1) MPa
LEFT direction {30(+5/-1)
kg/cm2}
R.H. swing PPC line throttle slow return valve may malfunction. Replace R.H. and
Clogging of R.H. swing L.H. of swing line throttle slow return valve, and check whether failure symptom
2 PPC line throttle, slow re- changes to make judgment.
turn valve
When removing the line throttle slow return valve, check its strainer for clogging.
L.H. swing PPC line throttle slow return valve may malfunction. Replace R.H. and
Clogging of L.H. swing L.H. of swing line throttle slow return valve, and check whether failure symptom
3 PPC line throttle, slow re- changes to make judgment.
turn valve
When removing the line throttle slow return valve, check its strainer for clogging.
Malfunction of control Spool of swing control valve may malfunction. Check that spool moves smoothly
4
valve (spool) and has no defects.
Be ready with engine stopped, then perform troubleshooting with engine at high
idle.
Swing relief 19.6±0.98
Malfunction of swing mo- pressure L.H. work equipment control lever: Swing LEFT relief, MPa
5
tor (safety valve) (pump pres- swing RIGHT relief {200±10
sure) kg/cm2}
If normal pressure is not obtained after adjustment, sealing of safety valve may be
defective.
Replace the suction valves of R.H. and L.H. swing motor, and check whether failure
Defective seal of swing
6 symptom changes to make judgment. When taking out the valve, check it for stick-
motor (suction valve)
ing and flaw.
Defective sealing of Replace the check valves of R.H. and L.H. swing motor, and check whether failure
7 swing motor (check symptom changes to make judgment. When taking out the valve, check it for stick-
valve) ing and flaw.

PC45MR-5, PC55MR-5 40-325

H-42 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWING-
ING 40 TROUBLESHOOTING

H-42 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWINGING

Failure Shock is large when upper structure stops swinging.
• Perform all troubleshooting with working mode to be set to power mode (P).
Related • Check that oil level in hydraulic tank is normal.
information • Perform troubleshooting with the hydraulic oil temperature at 45 to 55 °C.
• Swing PPC pressure can be checked with monitoring function. (Code: 09000)

No. Cause Procedure, measuring location, criteria and remarks

40-326 PC45MR-5, PC55MR-5

H-43 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUC-
40 TROUBLESHOOTING TURE STOPS SWINGING

H-43 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE

STOPS SWINGING
Failure Large unusual noise is heard when upper structure stops swinging.
• Set working mode to power mode (P), and perform all troubleshooting with power mode
Related (P).
information • Check that oil level in hydraulic tank is normal.
• Perform troubleshooting with the hydraulic oil temperature at 45 to 55 °C.

No. Cause Procedure, measuring location, criteria and remarks

Malfunction of back pres- Back pressure check valve in control valve may malfunctions. Check for stuck,
1
sure check valve seized, and damaged spool and loose spring.
• Malfunction of the safety valve of the swing motor is a possibility.
Defective swing motor
2 • If normal pressure is not obtained after adjustment, internal defect of safe-
(safety valve)
ty valve may be defective.
Replace the suction valves of R.H. and L.H. swing motor, and check whether failure
Defective seal of swing
3 symptom changes to make judgment. When taking out the valve, check it for stick-
motor (suction valve)
ing and flaw.
Defective swing machi- Check for unusual noise, unusual heat, and metallic powders in drained oil to make
4
nery judgment.

PC45MR-5, PC55MR-5 40-327

H-44 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARK-
ING BRAKE IS APPLIED) 40 TROUBLESHOOTING

H-44 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING

BRAKE IS APPLIED)
Failure Swing drift on a slope is large (while swing parking brake is applied).
• Set working mode to power mode (P), and perform all troubleshooting with power mode
(P).
Related • Check that the oil level in hydraulic tank is correct.
information • Perform troubleshooting with the hydraulic oil temperature at 45 to 55 °C.
• When the control lever for swing and arm IN is in NEUTRAL, the swing brake is applied
and swing is fixed by disc brake.

No. Cause Procedure, measuring location, criteria and remarks

Be ready with engine stopped, then perform troubleshooting with engine at high
idle.
Swing motor 2.94
Malfunction of swing mo- parking (+0.49/-0.1)
1 L.H. work equipment control lever: Operate arm IN di-
tor parking brake brake re- MPa {30
rection or swing RIGHT/LEFT direction
lease pres- (+5/-1)
sure kg/cm2}
If no failure is found by preceding checks, the brake may malfunction. Check it.

40-328 PC45MR-5, PC55MR-5

H-45 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARK-
40 TROUBLESHOOTING ING BRAKE IS RELEASED)

H-45 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING

BRAKE IS RELEASED)
Failure Swing drift on a slope is large (while swing parking brake is released).
• Set working mode to power mode (P), and perform all troubleshooting with power mode
(P).
Related • Check that the oil level in hydraulic tank is correct.
information • Perform troubleshooting with the hydraulic oil temperature at 45 to 55 °C.
• While operating arm IN, swing brake is released and swing is hold by hydraulic pressure
only.

No. Cause Procedure, measuring location, criteria and remarks

Malfunction of control Spool of swing control valve may malfunction. Check that spool moves smoothly
1
valve (spool) and has no defects.
Be ready with engine stopped, then perform troubleshooting with engine at high
idle.
Swing relief 19.6±0.98
Malfunction of swing mo- pressure L.H. work equipment control lever: Swing LEFT relief, MPa
2
tor (safety valve) (pump pres- swing RIGHT relief {200±10
sure) kg/cm2}
If normal pressure is not obtained after adjustment, sealing of safety valve may be
defective.
Replace the suction valves of R.H. and L.H. swing motor, and check whether failure
Defective seal of swing
3 symptom changes to make judgment. When taking out the valve, check it for stick-
motor (suction valve)
ing and flaw.
Defective sealing of Replace the check valves of R.H. and L.H. swing motor, and check whether failure
4 swing motor (check symptom changes to make judgment. When taking out the valve, check it for stick-
valve) ing and flaw.

PC45MR-5, PC55MR-5 40-329

INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S
MODE) 40 TROUBLESHOOTING

TROUBLESHOOTING OF ENGINE (S-MODE)

INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE)
The following information is summarized in the troubleshooting table. Before performing troubleshooting, under-
stand that information fully.
Failure Failure symptom that appears on engine
Related infor-
Information on occurred failure or troubleshooting
mation

Cause Point to check, remarks Remedy

1
<Contents of description>
2 Probable cause of failure
• Contents of check to deter-
(Each number is serial • Actions to eliminate probable
3 mine probable causes
number, not priority se- cause of failure
4 quence.) • Remarks for determination of
probable cause
5

40-330 PC45MR-5, PC55MR-5

S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS
40 TROUBLESHOOTING TURNED TO START POSITION

S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO

START POSITION
Failure Engine does not crank when starting switch is turned to "START" position
• See E-mode in "ENGINE DOES NOT START (ENGINE DOES NOT CRANK)" for electri-
Related
cal system troubleshooting
information
• If any failure code is displayed, perform troubleshooting for that code first.

No. Cause Point to check, remarks Remedy

When starting switch is turned to START, starting mo- Perform troubleshooting of
tor pinion does not pop out. “ENGINE DOES NOT
Defective starting circuit
1 START (ENGINE DOES
wiring system
NOT CRANK)” in E mode,
and take corrective action.
• Starting motor pinion makes grating noise
(When starting switch is turned to START posi-
tion, starting motor pinion pops out).
• Starting motor pinion comes off halfway (When
Perform troubleshooting of
starting switch is turned to START position,
“ENGINE DOES NOT
Defective starting motor starting motor pinion pops out).
2 START (ENGINE DOES
(safety relay portion) • Starting motor makes flapping sound and does NOT CRANK)” in E mode,
not turn (When starting switch is turned to and take corrective action.
START position, starting motor pinion pro-
trudes) (Reference: “Flapping sound” means
sound made when starting motor pinion pops in
and out)
If starting motor pinion makes grating noise and the
Breakage of flywheel ring Replace if the item is bro-
3 starting motor does not turn, visually check the fly-
gear ken
wheel ring gear.
Disconnect the inlet and outlet gas piping of EGR cool-
er to check if water containing coolant is draining.
A crack on the EGR cool- After EGR cooler replace-
4 er (Reference: coolant REMARK ment, drain the water in
contained in exhaust) the engine cylinder.
Moisture in exhaust gas may be condensed, but this
is not a failure. Check if it is coolant or not.

PC45MR-5, PC55MR-5 40-331

S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT 40 TROUBLESHOOTING

S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT

Failure Engine cranks but no exhaust gas comes out.
Related
If any failure code is displayed, perform troubleshooting for that code first.
information

No. Cause Point to check, remarks Remedy

NOTICE
Be sure to check for above “Defective common
rail”.
Check common rail pressure with machine monitor. If it
8 Defective supply pump does not increase even during cranking, supply pump Supply pump replacement
is defective.
REMARK
Common rail pressure can be checked with monitor-
ing function (Code: 36400 (MPa)).
When common rail pressure (code: 36400 “Common Loosen common rail side
Defective air bleeding
rail pressure”) is checked on monitor, pressure does of injection pipe and high-
9 from common rail or in-
not drop after stopping (Pressure does not drop, if air pressure pipe mounting
jection pipe
is left). nuts to bleed air.

40-332 PC45MR-5, PC55MR-5

S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MIS-
40 TROUBLESHOOTING FIRING: ENGINE CRANKS BUT DOES NOT START)

S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIR-
ING: ENGINE CRANKS BUT DOES NOT START)
Failure Fuel is being injected but engine does not start (misfiring: engine cranks but does not start).
Related
If any failure code is displayed, perform troubleshooting for that code first.
information

No. Cause Point to check, remarks Remedy

Gravity of electrolyte and voltage of battery are low. Filling of battery electro-
1 Defective battery
lyte
2 Fuel level is low. If fuel tank is checked, it is empty. Refueling
Fuel tank cap air bleeding hole is clogged. Flush air breather hole in
Clogging fuel tank cap air
3 fuel tank cap surrounding
bleeding hole
area.
Clogged fuel filter ele- Check used hours of fuel filter element. If it is used Fuel filter element replace-
4
ment over specified time, fuel filter element may be clogged. ment
Foreign materials are If drain fuel from fuel tank, rust or water comes out.
5 Fuel replacement
mixed into fuel.
When performing bleeding air from the fuel system, air • Perform air bleeding
Air mixed in fuel piping comes out. (For details, see Testing and adjusting, operation
6 “Bleeding air from fuel system”).
system • Correct or replace
fuel piping
Leakage from fuel piping Fuel leaks from fuel piping. (For details, see Testing Correct or replace fuel pip-
7
system and adjusting, “Test fuel circuit for leakage”). ing related parts
Clogged air cleaner ele- Air cleaner dust indicator is at caution level. Air cleaner element check
8
ment and cleaning
• Installation part of intake air heater is not
warmed during preheat operation.
Defective intake air heat- Intake air heater replace-
9 • Engine preheating monitor does not operate
er ment
normally during preheat operation or when it is
low temperature.
• Check valve clearance (Reference: See Testing
and adjusting, “Testing and adjusting valve
Worn valve, rocker arm, clearance”). Valve or rocker arm re-
10
etc. placement
• When engine is operated, unusual noise is
heard from around cylinder head.
Check compression pressure (Reference: See “TEST-
Piston ring and piston re-
11 Defective piston ring ING AND ADJUSTING”, “Testing compression pres-
placement
sure”).
Perform cylinder cutout mode operation to identify cyl-
Defective injector (clog-
inder that does not change in speed (see “TESTING
12 ged injector, defective Replace injector.
AND ADJUSTING”, “HANDLING CYLINDER CUTOUT
spray)
MODE OPERATION”).
Defective engine control- In case of an internal defect, troubleshooting is impos- Engine controller replace-
13
ler sible as an assembly. Replace whole assembly. ment

PC45MR-5, PC55MR-5 40-333

S-4 ENGINE STARTABILITY IS POOR 40 TROUBLESHOOTING

S-4 ENGINE STARTABILITY IS POOR

Failure Engine startability is poor.
• If any failure code is displayed, perform troubleshooting for that code first.
Related • Common rail fuel injection system (CRI) controls fuel injection timing electronically. Even
information when start operation is performed, engine does not start until crankshaft is rotated at least
twice. This is not abnormal.

No. Cause Point to check, remarks Remedy

Gravity of electrolyte and voltage of battery are low. Filling of battery electro-
1 Defective battery
lyte
2 Fuel level is low. If fuel tank is checked, it is empty. Refueling
Unspecified fuel is used. Use recommended fuel
3 Unspecified fuel is used. described in Operation
and Maintenance Manual.
Fuel tank cap air bleeding hole is clogged. Flush air breather hole in
Clogging fuel tank cap air
4 fuel tank cap surrounding
bleeding hole
area.
Clogged fuel filter ele- Check used hours of fuel filter element. If it is used Fuel filter element replace-
5
ment over specified time, fuel filter element may be clogged. ment
Foreign materials are If drain fuel from fuel tank, rust or water comes out.
6 Fuel replacement
mixed into fuel.
When performing bleeding air from the fuel system, air • Perform air bleeding
Air mixed in fuel piping comes out. (For details, see Testing and adjusting, operation
7 “Bleeding air from fuel system”).
system • Correct or replace
fuel piping
Leakage from fuel piping Fuel leaks from fuel piping. (For details, see Testing Correct or replace fuel pip-
8
system and adjusting, “Test fuel circuit for leakage”). ing related parts
Check leakage from common rail pressure limiter. For
9 Defective common rail details, see Testing and adjusting, “Testing fuel deliv- Common rail replacement
ery, return rate, and leakage”.

NOTICE
Be sure to check for above “Defective common
rail”.
Check common rail pressure with machine monitor. If it
10 Defective supply pump does not increase even during cranking, supply pump Supply pump replacement
is defective.
REMARK
Common rail pressure can be checked with monitor-
ing function (Code: 36400 (MPa)).
Clogged air cleaner ele- Air cleaner dust indicator is at caution level. Air cleaner element check
11
ment and cleaning
• Installation part of intake air heater is not
warmed during preheat operation.
Defective intake air heat- Intake air heater replace-
12 • Engine preheating monitor does not operate
er ment
normally during preheat operation or when it is
low temperature.

40-334 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING S-4 ENGINE STARTABILITY IS POOR

No. Cause Point to check, remarks Remedy

Disconnect the inlet and outlet gas piping of EGR cool-
er to check if water containing coolant is draining.
A crack on the EGR cool- After EGR cooler replace-
13 er (Reference: coolant REMARK ment, drain the water in
contained in exhaust) the engine cylinder.
Moisture in exhaust gas may be condensed, but this
is not a failure. Check if it is coolant or not.
• Some cylinder is found to be cool when exhaust
manifolds are touched by hand immediately af-
ter engine is started.
14 Defective injector • Perform cylinder cutout mode operation to iden- Replace injector.
tify cylinder that does not change in speed (see
“TESTING AND ADJUSTING”, “HANDLING
CYLINDER CUTOUT MODE OPERATION”).
Defective engine control- In case of an internal defect, troubleshooting is impos- Engine controller replace-
15
ler sible as an assembly. Replace whole assembly. ment
• Measure compression pressure (See Standard
value table). (Reference: See Testing and ad-
Defective contact of justing, “Testing compression pressure”.) Valve or valve seat repair
16
valve and valve seat • Check valve clearance (Reference: See Testing or replacement
and adjusting, “Testing and adjusting valve
clearance”).
• Check exhaust gas color.(Reference: See
“TESTING AND ADJUSTING”, “Checking ex-
haust gas color”).
Piston ring and piston re-
17 Defective piston ring • Measure compression pressure (See standard
placement
value table). (Reference: See “TESTING AND
ADJUSTING”, “Testing compression pressure”.)
• Check piston ring and piston ring groove.

PC45MR-5, PC55MR-5 40-335

S-5 ENGINE DOES NOT PICK UP SMOOTHLY 40 TROUBLESHOOTING

S-5 ENGINE DOES NOT PICK UP SMOOTHLY

Failure Engine does not pick-up smoothly.
Related
If any failure code is displayed, perform troubleshooting for that code first.
information

No. Cause Point to check, remarks Remedy

NOTICE
Be sure to check for above “Defective common
rail”.
Check common rail pressure with machine monitor. If it
8 Defective supply pump does not increase even during cranking, supply pump Supply pump replacement
is defective.
REMARK
Common rail pressure can be checked with monitor-
ing function (Code: 36400 (MPa)).
• Some cylinder is found to be cool when exhaust
manifolds are touched by hand immediately af-
ter engine is started.
9 Defective injector • Perform cylinder cutout mode operation to iden- Replace injector.
tify cylinder that does not change in speed (see
“TESTING AND ADJUSTING”, “HANDLING
CYLINDER CUTOUT MODE OPERATION”).
• When engine is operated, unusual noise is
heard from around cylinder head.
Defective valve clear- Valve clearance adjust-
10 • Check valve clearance (Reference: See Testing ment
ance
and adjusting, “Testing and adjusting valve
clearance”).

40-336 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING S-5 ENGINE DOES NOT PICK UP SMOOTHLY

No. Cause Point to check, remarks Remedy

• Measure compression pressure (See Standard
value table). (Reference: See Testing and ad-
Defective contact of justing, “Testing compression pressure”.) Valve or valve seat repair
11
valve and valve seat • Check valve clearance (Reference: See Testing or replacement
and adjusting, “Testing and adjusting valve
clearance”).
• Check exhaust gas color.(Reference: See
“TESTING AND ADJUSTING”, “Checking ex-
haust gas color”).
Piston ring and piston re-
12 Defective piston ring • Measure compression pressure (See standard
placement
value table). (Reference: See “TESTING AND
ADJUSTING”, “Testing compression pressure”.)
• Check piston ring and piston ring groove.
Defective engine control- In case of an internal defect, troubleshooting is impos- Engine controller replace-
13
ler sible as an assembly. Replace whole assembly. ment

PC45MR-5, PC55MR-5 40-337

S-6 ENGINE STOPS DURING OPERATION 40 TROUBLESHOOTING

S-6 ENGINE STOPS DURING OPERATION

Failure Engine stops during operation.
Related
If any failure code is displayed, perform troubleshooting for that code first.
information

No. Cause Point to check, remarks Remedy

1 Fuel level is low. If fuel tank is checked, it is empty. Refueling
Fuel tank cap air bleeding hole is clogged. Flush air breather hole in
Clogging fuel tank cap air
2 fuel tank cap surrounding
bleeding hole
area.
Clogged fuel filter ele- Check used hours of fuel filter element. If it is used Fuel filter element replace-
3
ment over specified time, fuel filter element may be clogged. ment
Foreign materials are If drain fuel from fuel tank, rust or water comes out.
4 Fuel replacement
mixed into fuel.
When performing bleeding air from the fuel system, air • Perform air bleeding
Air mixed in fuel piping comes out. (For details, see Testing and adjusting, operation
5 “Bleeding air from fuel system”).
system • Correct or replace
fuel piping
Leakage from fuel piping Fuel leaks from fuel piping. (For details, see Testing Correct or replace fuel pip-
6
system and adjusting, “Test fuel circuit for leakage”). ing related parts
See Testing and adjusting, “Testing fuel discharge rate, Supply pump and pres-
7 Defective supply pump
return rate, and leakage” sure limiter replacement
Visually check for damages of air intake hose. Air intake hose replace-
8 Defective air intake hose.
ment
Defective air intake mani- Check for internal damages of air intake manifold. Air intake manifold re-
9
fold placement
Check exhaust pipes for damage and exhaust gas
Exhaust piping replace-
10 Defective exhaust pipe. leakage (Check heat insulation cover and soot on heat
ment
insulation plate)
Broken valve or rocker Check valve and rocker arm (when stops with unusual Valve or rocker arm re-
11
arm noise). placement
• Oil drained from oil pan contains metallic pow-
Breakage or seizure of der.
Piston and connecting rod
12 piston and connecting • Remove oil pan and check piston and connect- replacement
rod ing rod (Reference: Stopping with unusual
noise or stopping caused by overheating)
• Metal particles are contained in oil drained from
Breakage or seizure of oil pan. Crankshaft main bearing
13
crankshaft main bearing • Remove oil pan and check crankshaft main replacement
bearing.
Defective engine control- Check power supply wiring of engine controller. Correct engine controller
14
ler power supply wiring power supply wiring
Check starting switch wiring. Perform troubleshooting of
“ENGINE DOES NOT
Defective starting switch
15 START (ENGINE DOES
wiring
NOT CRANK)” in E mode,
and take corrective action.
Malfunction of hydraulic See H mode, “Engine speed lowers significantly or en- Diagnose and take rem-
16
system gine stalls”. edies for H mode

40-338 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING S-7 ENGINE RUNS ROUGH OR IS UNSTABLE

S-7 ENGINE RUNS ROUGH OR IS UNSTABLE

Failure Engine runs rough or is unstable.
Related
If any failure code is displayed, perform troubleshooting for that code first.
information

No. Cause Point to check, remarks Remedy

PC45MR-5, PC55MR-5 40-339

S-8 ENGINE LACKS POWER 40 TROUBLESHOOTING

S-8 ENGINE LACKS POWER

Failure Engine lacks power.
Related
If any failure code is displayed, perform troubleshooting for that code first.
information

No. Cause Point to check, remarks Remedy

1 Fuel level is low. If fuel tank is checked, it is empty. Refueling
Fuel tank cap air bleeding hole is clogged. Flush air breather hole in
Clogging fuel tank cap air
2 fuel tank cap surrounding
bleeding hole
area.
Clogged fuel filter ele- Check used hours of fuel filter element. If it is used Fuel filter element replace-
3
ment over specified time, fuel filter element may be clogged. ment
Foreign materials are If drain fuel from fuel tank, rust or water comes out.
4 Fuel replacement
mixed into fuel.
When performing bleeding air from the fuel system, air • Perform air bleeding
Air mixed in fuel piping comes out. (For details, see Testing and adjusting, operation
5 “Bleeding air from fuel system”).
system • Correct or replace
fuel piping
Leakage from fuel piping Fuel leaks from fuel piping. (For details, see Testing Correct or replace fuel pip-
6
system and adjusting, “Test fuel circuit for leakage”). ing related parts
See Testing and adjusting, “Testing fuel discharge rate, Supply pump and pres-
7 Defective supply pump
return rate, and leakage” sure limiter replacement
Clogged air cleaner ele- Air cleaner dust indicator is at caution level. Air cleaner element check
8
ment and cleaning
Check air cleaner and rectifying wire net for deforma- Air cleaner repair or re-
9 Defective air cleaner
tion. placement
Visually check for damages of air intake hose. Air intake hose replace-
10 Defective air intake hose.
ment
Defective air intake mani- Check for internal damages of air intake manifold. Air intake manifold re-
11
fold placement
Air suction from the air intake pipe. Repair or replacement of
Air intake pipe and joint
12 air intake pipe and joint
part failures.
part.
Defective installation of Air leakage through mounting portion of charge pres- Repair installation of
13
charge pressure sensor sure sensor charge pressure sensor
Check exhaust pipes for damage and exhaust gas
Exhaust piping replace-
14 Defective exhaust pipe. leakage (Check heat insulation cover and soot on heat
ment
insulation plate)
Gas leakage from EGR Gas leaking from EGR piping.
15 Replace EGR piping
piping
• When engine is operated, unusual noise is
heard from around cylinder head.
Defective valve clear- Valve clearance adjust-
16 • Check valve clearance (Reference: See Testing ment
ance
and adjusting, “Testing and adjusting valve
clearance”).

40-340 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING S-8 ENGINE LACKS POWER

No. Cause Point to check, remarks Remedy

• Some cylinder is found to be cool when exhaust
manifolds are touched by hand immediately af-
ter engine is started.
17 Defective injector • Perform cylinder cutout mode operation to iden- Replace injector.
tify cylinder that does not change in speed (see
“TESTING AND ADJUSTING”, “HANDLING
CYLINDER CUTOUT MODE OPERATION”).
Defective engine control- In case of an internal defect, troubleshooting is impos- Engine controller replace-
18
ler sible as an assembly. Replace whole assembly. ment
• Measure compression pressure (See Standard
value table). (Reference: See Testing and ad-
Defective contact of justing, “Testing compression pressure”.) Valve or valve seat repair
19
valve and valve seat • Check valve clearance (Reference: See Testing or replacement
and adjusting, “Testing and adjusting valve
clearance”).
• Check exhaust gas color.(Reference: See
“TESTING AND ADJUSTING”, “Checking ex-
haust gas color”).
Piston ring and piston re-
20 Defective piston ring • Measure compression pressure (See standard
placement
value table). (Reference: See “TESTING AND
ADJUSTING”, “Testing compression pressure”.)
• Check piston ring and piston ring groove.

PC45MR-5, PC55MR-5 40-341

S-9 KDPF GETS CLOGGED IN A SHORT TIME 40 TROUBLESHOOTING

S-9 KDPF GETS CLOGGED IN A SHORT TIME

No. Cause Point to check, remarks Remedy
Unspecified fuel is used. Use recommended fuel
1 Unspecified fuel is used. described in Operation
and Maintenance Manual.
Foreign materials are If drain fuel from fuel tank, rust or water comes out.
2 Fuel replacement
mixed into fuel.
Check air cleaner and rectifying wire net for deforma- Air cleaner repair or re-
3 Defective air cleaner
tion. placement
Check exhaust pipes for damage and exhaust gas
Exhaust piping replace-
4 Defective exhaust pipe. leakage (Check heat insulation cover and soot on heat
ment
insulation plate)
Air suction from the air intake pipe. Repair or replacement of
Air intake pipe and joint
5 air intake pipe and joint
part failures.
part.
Gas leakage from EGR Gas leaking from EGR piping.
6 Replace EGR piping
piping
• Some cylinder is found to be cool when exhaust
manifolds are touched by hand immediately af-
ter engine is started.
7 Defective injector • Perform cylinder cutout mode operation to iden- Replace injector.
tify cylinder that does not change in speed (see
“TESTING AND ADJUSTING”, “HANDLING
CYLINDER CUTOUT MODE OPERATION”).
When checking fuel return rate, fuel return rate is ex-
Defective fuel return pip- Fuel return piping repair or
8 cessive. (Reference: See Testing and adjusting, “Test-
ing replacement
ing fuel return rate and leakage”.)
Replace a sensor, and check if it operates normally
defective temperature Mass temperature sensor
9 (failure code may be displayed due to dust attached to
sensor replacement
sensor).
• When engine is operated, unusual noise is
heard from around cylinder head.
Defective valve clear- Valve clearance adjust-
10 • Check valve clearance (Reference: See Testing ment
ance
and adjusting, “Testing and adjusting valve
clearance”).
• Measure compression pressure (See Standard
value table). (Reference: See Testing and ad-
Defective contact of justing, “Testing compression pressure”.) Valve or valve seat repair
11
valve and valve seat • Check valve clearance (Reference: See Testing or replacement
and adjusting, “Testing and adjusting valve
clearance”).
• Check exhaust gas color.(Reference: See
“TESTING AND ADJUSTING”, “Checking ex-
haust gas color”).
Piston ring and piston re-
12 Defective piston ring • Measure compression pressure (See standard
placement
value table). (Reference: See “TESTING AND
ADJUSTING”, “Testing compression pressure”.)
• Check piston ring and piston ring groove.

40-342 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE

S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE

Failure Engine oil consumption is excessive
Related
If any failure code is displayed, perform troubleshooting for that code first.
information

No. Cause Point to check, remarks Remedy

Dust intake from air in- If air intake piping between air cleaner and engine is Air intake piping cleaning
1
take system removed, dust enters in piping. or replacement
Measure compression pressure (See standard value
Breakage or wear of pis- Piston ring replacement or
2 table). (Reference: See “TESTING AND ADJUSTING”,
ton ring repair
“Testing compression pressure”.)
3 Oil leakage out of engine Check for oil leakage. Oil leakage part repair
Check for oil leakage from oil filter. Oil filter re installation or
4 Oil leakage from oil filter
replacement
Oil leakage from oil pip- Check for oil leakage from oil piping Oil piping repair or re-
5
ing placement
Oil leakage from oil drain Check oil leakage from oil drain plug.
6 Retighten oil drain plug
plug
Check for oil leakage from oil pan. Oil pan repair or replace-
7 Oil leakage from oil pan
ment
Oil leakage from cylinder Check for oil leakage from cylinder head. Cylinder head repair or re-
8
head placement
Wear of damage of rear Oil in clutch chamber or damper chamber on mounted Rear oil seal repair or re-
9
oil seal machine side is increased. placement
• Oil is mixed in coolant.
• Remove oil cooler, and visually check for oil
Oil leakage from oil cool-
10 leakage from the oil cooler surface. Oil cooler replacement
er
• Check oil cooler for leakage by air pressure
test.
Oil leakage from EGR Outlet port is stained with oil after the EGR valve is dis-
11 EGR valve replacement
valve system connected.
• Check valve guide and stem seal.
Wear or damage of valve • Remove cylinder head and check guide internal Valve guide and stem seal
12
guide or stem seal surface and stem seal for damage (Reference: replacement
See Maintenance standard).

PC45MR-5, PC55MR-5 40-343

S-11 OIL BECOMES CONTAMINATED QUICKLY 40 TROUBLESHOOTING

S-11 OIL BECOMES CONTAMINATED QUICKLY

Failure Oil becomes contaminated quickly
Related
If any failure code is displayed, perform troubleshooting for that code first.
information

No. Cause Point to check, remarks Remedy

Unspecified fuel is used. Use recommended fuel
1 Unspecified fuel is used. described in Operation
and Maintenance Manual.
Oil out of specification is used Use recommended oil de-
Use of oil out of specifi-
2 scribed in Operation and
cation
Maintenance Manual.
Check exhaust gas color of KDPF (See standard value Perform troubleshooting of
Exhaust gas color of
3 table.) (Reference: See Testing and adjusting, “Ex- "KDPF gets clogged in a
KDPF is black.
haust gas color”). short times"
Check for high oil level (If oil is added too much, it be- Lower oil level to appropri-
4 Addition of too much oil
comes high temperature and is deteriorated rapidly). ate level.
Visually check oil cooler element for dirt (temperature Oil cooler element repair
5 Dirt on oil cooler element
rise caused by dirt of oil cooler element) or replacement
• Disconnect the EGR valve to check a stem
Wear in the EGR valve seal, guide, and system.
6 EGR valve replacement
guide • Outlet port is stained with oil after the EGR
valve is disconnected.
Measure compression pressure (See standard value
Breakage or wear of pis- Piston ring replacement or
7 table). (Reference: See “TESTING AND ADJUSTING”,
ton ring repair
“Testing compression pressure”.)
• Check valve guide and stem seal.
Wear or damage of valve • Remove cylinder head and check guide internal Valve guide and stem seal
8
guide or stem seal surface and stem seal for damage (Reference: replacement
See Maintenance standard).

40-344 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING S-12 FUEL CONSUMPTION IS EXCESSIVE

S-12 FUEL CONSUMPTION IS EXCESSIVE

Failure Fuel consumption is excessive.
Related
If any failure code is displayed, perform troubleshooting for that code first.
information

No. Cause Point to check, remarks Remedy

Leakage from injector (Reference: See “TESTING • Replace injector.
AND ADJUSTING”,“Testing fuel discharge, return and
Much leakage from injec- leakage”). • Excessive dust may
1 be in fuel. Confirm
tor
quality control of
fuel.
• Some cylinder is found to be cool when exhaust
manifolds are touched by hand immediately af-
ter engine is started.
2 Defective injector • Perform cylinder cutout mode operation to iden- Replace injector.
tify cylinder that does not change in speed (see
“TESTING AND ADJUSTING”, “HANDLING
CYLINDER CUTOUT MODE OPERATION”).

Fuel leakage from inside • Check if oil level is increasing.

3 Defective parts repair
of cylinder head • Check if there is smell of diesel fuel.
• Check if oil level is increasing or there is smell
Fuel leakage supply of diesel fuel. supply pump oil seal re-
4
pump oil seal part placement
• Check supply pump oil seal.
5 External fuel leakage Check for fuel leakage to outside of engine. Defective parts repair

PC45MR-5, PC55MR-5 40-345

S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOL-
ANT LEVEL GOES DOWN) 40 TROUBLESHOOTING

S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT

LEVEL GOES DOWN)
Failure Oil is in coolant (or coolant spurts back or coolant level goes down)
Related
If any failure code is displayed, perform troubleshooting for that code first.
information

No. Cause Point to check, remarks Remedy

Engine oil is increasing and milky. Perform troubleshooting of
“WATER MIXES INTO EN-
1 Engine oil is milky. GINE OIL (MILKY)” in S
mode, and take corrective
action.
Breakage of oil cooler el- Check oil cooler element. Oil cooler element re-
2
ement placement
• There are many bubbles in radiator and coolant
Breakage of cylinder blows back. Cylinder head replace-
3
head • Disassemble engine and check cylinder head ment
for abnormality by pressure test.
• Many bubbles and blow-back are found in radi-
ator. Cylinder head gasket re-
4 Breakage of head gasket
• Disassemble and inspect engine. Check cylin- placement
der head gasket for failure.

Cracking or hole caused • Engine oil is increasing and milky.

Cylinder block replace-
5 by pitting in cylinder • Disassemble engine and check inside of cylin- ment
block der block for cracking or hole caused by pitting.

40-346 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING S-14 OIL PRESSURE DROPS

S-14 OIL PRESSURE DROPS

Failure Oil pressure drops.
• If any failure code is displayed, perform troubleshooting for that code first.
Related
• Check if machine is operated on slopes steeper than angle specified in Operation and
information
Maintenance Manual.

No. Cause Point to check, remarks Remedy

Oil level in oil pan is insufficient.
1 Insufficient oil in oil pan Oil pressure monitor indicates low oil pressure on Oil refiling
slopes.
Check oil pressure sensor, wiring harness, and con- Oil pressure sensor, wiring
Defective oil pressure
2 nectors harness, and connectors
sensor or wiring harness
replacement
• Perform oil analysis and check for mixing of oil If fuel is mixed into oil,
perform troubleshooting of
• Oil smells of diesel fuel.
3 Fuel mixed in oil “FUEL MIXES INTO EN-
GINE OIL” in S mode, and
take corrective action.
• Perform oil analysis and check for mixing of wa- If water is mixed into oil,
ter perform troubleshooting of
“WATER MIXES INTO EN-
4 Water mixed in oil • Oil is milky.
GINE OIL (MILKY)” in S
mode, and take corrective
action.
• Check oil filter.
(Reference: Oil filter is used for more than specified
5 Clogged oil filter Oil filter replacement
period, oil is deteriorated badly, etc.)
• Oil filter may be blocked by water.
6 Clogged oil strainer Check oil strainer. Oil strainer cleaning
Flattened or clogged hy- Hydraulic piping is flattened or clogged. Hydraulic piping replace-
7
draulic piping ment
• Check oil pump (for wear or breakage of gear)
8 Defective oil pump Oil pump replacement
• Oil pump is heavy in turning or has play.
Check whether the valve spring is deformed and dam-
9 Defective regulator valve Regulator valve exchange
aged
Defective oil pump relief Valve and spring of oil pump relief valve are weakening Oil pump relief valve ex-
10
valve and damaged. change
Cracking in oil pump suc- Check around oil pump suction piping (for cracking ing Oil pump suction piping
11
tion piping piping). replacement
Defective seal between Check sealing portion.
12 oil pump and oil pump Seal replacement
suction piping
Leakage from EGR hy- Check EGR hydraulic piping. EGR hydraulic piping re-
13
draulic piping placement
• Check main journal bearing.
Wear of main journal Bearing of main journal re-
14 • Metal particles are contained in oil drained from placement
bearing
oil pan.

PC45MR-5, PC55MR-5 40-347

S-14 OIL PRESSURE DROPS 40 TROUBLESHOOTING

No. Cause Point to check, remarks Remedy

• Check pin journal bearing.
Wear of pin journal bear- Bearing of pin journal re-
15 • Oil drained from oil pan contains metallic pow-
ing placement
der.

40-348 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING S-15 FUEL MIXES INTO ENGINE OIL

S-15 FUEL MIXES INTO ENGINE OIL

Failure Fuel mixes into engine oil.
Related
• If any failure code is displayed, perform troubleshooting for that code first.
information

No. Cause Point to check, remarks Remedy

• Some cylinder is found to be cool when exhaust
manifolds are touched by hand immediately af-
ter engine is started.
1 Defective injector • Perform cylinder cutout mode operation to iden- Replace injector.
tify cylinder that does not change in speed (see
“TESTING AND ADJUSTING”, “HANDLING
CYLINDER CUTOUT MODE OPERATION”).
Fuel leakage from injec- Check injector and O-ring. Injector and O-ring re-
2
tor or O-ring (spill circuit) placement
Defective seal between Check of seal between injector and inspection pipe,
injector and inspection check of injection pipe for cracking
3 Repair or replacement
pipe, or cracked injection
pipe
Internal defect of supply Replace supply pump, and check if mixing of fuel is
4 Supply pump replacement
pump prevented.

PC45MR-5, PC55MR-5 40-349

S-16 WATER MIXES INTO ENGINE OIL (MILKY) 40 TROUBLESHOOTING

S-16 WATER MIXES INTO ENGINE OIL (MILKY)

Failure Water mixes into engine oil (milky)
• If oil mixes into coolant, perform troubleshooting for "Oil mixes into coolant".
Related
• If any failure code is displayed, perform troubleshooting for that code.
information
If coolant level lowers rapidly and coolant leakage is suspected, perform following troubleshooting.

No. Cause Point to check, remarks Remedy

• Water containing coolant is draining after dis-
connecting the inlet and outlet gas piping of
EGR cooler (check if it is antifreeze because it
may be condensed water).
A crack on the EGR cool-
1 (Reference: A crack in the EGR cooler, if any, may be EGR cooler replacement
er
caused by lowered coolant level in the coolant system.
Check if there is no water leakage from the piping of
the coolant system or radiator when the replacing the
EGR cooler.)
• Check oil cooler element and O-ring
Breakage of oil cooler el- Oil cooler element and O-
2 • Leakage form oil cooler is detected by pressure ring replacement
ement or O-ring
test.
Leakage through water Check water pump mechanical seal for leakage Mechanical sealed part of
3
pump mechanical seal water pump replacement
Clogged water pump Check water pump drain hole. Water pump drain hole
4
drain hole cleaning
Breakage of cylinder Disassemble engine and check cylinder head and Cylinder head and head
5
head or head gasket head gasket gasket replacement

Cracking or hole caused • Engine oil is increasing and milky.

Cylinder block replace-
6 by pitting in cylinder • Disassemble engine and check inside of cylin- ment
block der block for cracking or hole caused by pitting.

40-350 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING)

S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING)

Failure Coolant temperature rises too high (overheating)
Related
If any failure code is displayed, perform troubleshooting for that code first.
information

No. Cause Point to check, remarks Remedy

1 Clogged radiator core Check for clogging of radiator core and crushing of fin. Cleaning of radiator core
Thermostat does not open at cracking temperature.

2 Malfunction of thermostat
REMARK Thermostat replacement
For thermostat opening temperature, see Engine
Shop Manual
The error is detected in coolant temperature gauge Coolant temperature sen-
Defective coolant tem-
3 system, but measured coolant temperature in radiator sor, monitor or wiring har-
perature gauge
is normal. ness replacement
Fuel injection amount is excessive. Perform troubleshooting of
“FUEL CONSUMPTION
Increase of fuel injection
4 IS EXCESSIVE” in S
amount
mode, and take corrective
action.
5 Low coolant level Check coolant level for decrease. Refilling with coolant
Check coolant piping for coolant leakage. Coolant piping replace-
6 Coolant leakage
ment
Visually check water pump (check of water leakage
7 Broken water pump through shaft seal, breakage of impeller, breakage of Water pump replacement
shaft)
Overheat due to increase Check for defective mass temperature sensor.
in EGR ratio (EGR
amount against fresh air Mass temperature sensor
8
intake amount) caused replacement
by defective temperature
sensor
Overheat caused by in- Check air cleaner and rectifying wire net for deforma-
crease of EGR ratio tion.
Air cleaner repair or re-
9 (quantity of EGR to fresh
placement
intake air) caused by de-
formation of air cleaner
Check if there are many bubbles in radiator and if cool- Perform troubleshooting of
Defective cylinder head ant blows back. “OIL IS IN COOLANT” in
10
or head gasket S mode, and take correc-
tive action.
• Check exhaust gas color.(Reference: See
“TESTING AND ADJUSTING”, “Checking ex-
haust gas color”).
Piston ring and piston re-
11 Defective piston ring • Measure compression pressure (See standard
placement
value table). (Reference: See “TESTING AND
ADJUSTING”, “Testing compression pressure”.)
• Check piston ring and piston ring groove.

PC45MR-5, PC55MR-5 40-351

S-18 UNUSUAL NOISE IS HEARD 40 TROUBLESHOOTING

S-18 UNUSUAL NOISE IS HEARD

Failure Unusual noise is heard.
• Check place of sound source, inside or outside, then perform troubleshooting.
• While engine is not warmed up sufficiently, it is operated in warm-up mode and it gener-
Related ates a little larger sound. This is not abnormal.
information • When engine is accelerated, it is set in acceleration mode and it generates a little larger
sound for approximately 3 to 5 seconds. This is not abnormal.
• If any failure code is displayed, perform troubleshooting for that code first.

No. Cause Point to check, remarks Remedy

• Gas leakage from following parts; between cyl-
Gas leakage from each inder head and exhaust manifold Problematic portions re-
1
part of the piping • Gas leakage from EGR piping or air intake pip- pair or replacement
ing
Vibration of exhaust pip- Confirm the presence of vibration by visual check Check and retighten pip-
2
ing and exhaust bellows ing fixed bracket
Check internal KDPF. KDPF cleaning or replace-
3 KDPF broken internally
ment
• Some cylinder is found to be cool when exhaust
manifolds are touched by hand immediately af-
ter engine is started.
4 Defective injector • Perform cylinder cutout mode operation to iden- Replace injector.
tify cylinder that does not change in speed (see
“TESTING AND ADJUSTING”, “HANDLING
CYLINDER CUTOUT MODE OPERATION”).
Defective valve clear- Check valve clearance (Reference: See Testing and Valve clearance adjust-
5
ance adjusting, “Testing and adjusting valve clearance”). ment
Seizure of pin bushing, Check inside of oil pan for metallic powder.
Damaged parts repair or
6 front bearing, or main
replacement
bearing
1. If metal particles are found in oil pan or oil filter,
overhaul engine and check piston rings and cyl-
Worn piston ring or cylin- inder block. Replace piston ring, repair
7
der block 2. Measure pressure (See Standard value table) or replace cylinder block
(Reference: See Testing and adjusting, “Testing
compression pressure”)
Broken valve or rocker Overhaul engine and check valve and rocker arm Valve or rocker arm re-
8
arm parts. placement
Broken peripheral parts Overhaul engine and inspect idler gear parts.
9 Idler gear replacement
of idler gear
Check if alternator belt is damaged or interfered Replace alternator belt
10 Defective alternator belt
and damaged parts

40-352 PC45MR-5, PC55MR-5

40 TROUBLESHOOTING S-19 VIBRATION IS EXCESSIVE

S-19 VIBRATION IS EXCESSIVE

Failure Vibration is excessive.
• If unusual noise is heard and vibration is excessive, perform troubleshooting for "Unusual
Related
noise is heard" as well.
information
• If any failure code is displayed, perform troubleshooting for that code first.

No. Cause Point to check, remarks Remedy

Loose engine mounting Visually check engine mounting bolts for looseness
Retighten bolts or cush-
1 bolts or defective cush- and cushions for cracks and hardening.
ions replacement
ions
Abnormality of output Check output shaft and damper for internal damage.
Defective parts replace-
2 shaft and inside of damp-
ment
er
Misalignment and facial Measure misalignment and facial runout at connection
runout at connection of of engine output side. Defective parts replace-
3
engine output side is out ment
of standard range.
• Some cylinder is found to be cool when exhaust
manifolds are touched by hand immediately af-
ter engine is started.
4 Defective injector • Perform cylinder cutout mode operation to iden- Replace injector.
tify cylinder that does not change in speed (see
“TESTING AND ADJUSTING”, “HANDLING
CYLINDER CUTOUT MODE OPERATION”).
Wear of main bearing If metallic powder is found in oil pan and oil filler, disas-
Damaged parts repair and
5 and connecting rod bear- semble engine and check it.
replacement
ing
Broken valve or rocker If there is metallic powder in oil pan or oil filter, open Damaged parts repair and
6
arm head cover and check valve and rocker arm. replacement
If metal particles are found in oil pan or oil filter, over- Camshaft bushings re-
7 Worn camshaft bushing
haul engine and check camshaft bushings. placement

PC45MR-5, PC55MR-5 40-353

S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT 40 TROUBLESHOOTING

S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT

Failure Air cannot be bled from fuel circuit.
Related
If any failure code is displayed, perform troubleshooting for that code first.
information

No. Cause Point to check, remarks Remedy

1 Fuel level is low. If fuel tank is checked, it is empty. Refueling
Looseness of fuel prefil- Check for loosened fuel prefilter drain valve (Air mixed
2 Close drain valve
ter drain valve for loosened fuel prefilter drain valve).
Clogged fuel filter ele- Check used hours of fuel filter element. If it is used Fuel filter element replace-
3
ment over specified time, fuel filter element may be clogged. ment
When performing bleeding air from the fuel system, air • Perform air bleeding
Air mixed in fuel piping comes out. (For details, see Testing and adjusting, operation
4 “Bleeding air from fuel system”).
system • Correct or replace
fuel piping
Leakage from fuel piping Fuel leaks from fuel piping. (For details, see Testing Correct or replace fuel pip-
5
system and adjusting, “Test fuel circuit for leakage”). ing related parts
6 Feed pomp error. Feed pump does not operate. Feed pump replacement.

40-354 PC45MR-5, PC55MR-5

50 DISASSEMBLY AND ASSEMBLY

PC45MR-5, PC55MR-5 50-1

50 DISASSEMBLY AND ASSEM-
CONTENTS BLY

CONTENTS
ABBREVIATION LIST .................................................................................................................................... 50-5
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY ................................................................50-11
HOW TO READ THIS MANUAL.............................................................................................................50-11
COATING MATERIALS LIST................................................................................................................. 50-13
SPECIAL TOOLS LIST ......................................................................................................................... 50-17
SKETCHES OF SPECIAL TOOLS........................................................................................................ 50-22
ENGINE AND COOLING SYSTEM.............................................................................................................. 50-23
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY ......................................................................... 50-23
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY ............................................................. 50-23
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY ............................................................ 50-26
REMOVE AND INSTALL STARTER ASSEMBLY .................................................................................. 50-30
METHOD FOR REMOVING STARTER ASSEMBLY...................................................................... 50-30
METHOD FOR INSTALLING STARTER ASSEMBLY..................................................................... 50-31
REMOVE AND INSTALL RADIATOR ASSEMBLY ................................................................................ 50-32
METHOD FOR REMOVING RADIATOR ASSEMBLY .................................................................... 50-32
METHOD FOR INSTALLING RADIATOR ASSEMBLY ................................................................... 50-35
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY ....................................................... 50-39
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY ........................................... 50-39
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY.......................................... 50-42
REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY ....................................................... 50-46
METHOD FOR REMOVING ENGINE AND MAIN PUMP ASSEMBLY ........................................... 50-46
METHOD FOR INSTALLING ENGINE AND MAIN PUMP ASSEMBLY.......................................... 50-52
REMOVE AND INSTALL FUEL TANK ASSEMBLY ............................................................................... 50-59
METHOD FOR REMOVING FUEL TANK ASSEMBLY................................................................... 50-59
METHOD FOR INSTALLING FUEL TANK ASSEMBLY.................................................................. 50-61
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY .................................................................... 50-64
POWER TRAIN............................................................................................................................................ 50-65
REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY ....................................... 50-65
METHOD FOR REMOVING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY ........................... 50-65
METHOD FOR INSTALLING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY .......................... 50-67
REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY............................. 50-69
METHOD FOR REMOVING SWING MOTOR AND SWING MACHINERY ASSEMBLY ................ 50-69
METHOD FOR INSTALLING SWING MOTOR AND SWING MACHINERY ASSEMBLY ............... 50-70
DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY ................................................. 50-71
METHOD FOR DISASSEMBLING SWING MACHINERY ASSEMBLY .......................................... 50-71
METHOD FOR ASSEMBLING SWING MACHINERY ASSEMBLY ................................................ 50-74
REMOVE AND INSTALL SWING CIRCLE ASSEMBLY ........................................................................ 50-78
METHOD FOR REMOVING SWING CIRCLE ASSEMBLY ............................................................ 50-78
METHOD FOR INSTALLING SWING CIRCLE ASSEMBLY ........................................................... 50-78
UNDERCARRIAGE AND FRAME................................................................................................................ 50-80
DISASSEMBLE AND ASSEMBLE RECOIL SPRING............................................................................ 50-80
METHOD FOR DISASSEMBLING AND ASSEMBLING RECOIL SPRING .................................... 50-80
METHOD FOR ASSEMNLING RECOIL SPRING ASSEMBLY ...................................................... 50-81
SEPARATION AND CONNECTION OF TRACK ASSEMBLY................................................................ 50-83
METHOD FOR SEPARATING TRACK ASSEMBLY ....................................................................... 50-83
METHOD FOR INSTALLING TRACK ASSEMBLY......................................................................... 50-83
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY ......................................................................... 50-85
METHOD FOR DISASSEMBLING IDLER ASSEMBLY .................................................................. 50-85
METHOD FOR ASSEMBLING IDLER ASSEMBLY........................................................................ 50-86
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY ........................................................ 50-88
METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY ................................................. 50-88
METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY ....................................................... 50-89
DISASSEMBLEAND ASSEMBLE CARRIER ROLLER ASSEMBLY ..................................................... 50-91
METHOD FOR DISASSEMBLING CARRIER ROLLER ASSEMBLY ............................................. 50-91
METHOD FOR ASSEMBLING CARRIER ROLLER ASSEMBLY ................................................... 50-92
REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY ................................................................ 50-94

50-2 PC45MR-5, PC55MR-5

50 DISASSEMBLY AND ASSEM-
BLY CONTENTS

METHOD FOR REMOVING REVOLVING FRAME ASSEMBLY .................................................... 50-94

METHOD FOR INSTALLING REVOLVING FRAME ASSEMBLY ................................................... 50-95
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY................................................................... 50-97
METHOD FOR REMOVING COUNTERWEIGHT ASSEMBLY ...................................................... 50-97
METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY ....................................................50-100
HYDRAULIC SYSTEM................................................................................................................................50-105
REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY .........................................................50-105
METHOD FOR REMOVING CENTER SWIVEL JOINT ASSEMBLY .............................................50-105
METHOD FOR INSTALLING CENTER SWIVEL JOINT ASSEMBLY............................................50-106
DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY ..........................................50-109
METHOD FOR DISASSEMBLING CENTER SWIVEL JOINT ASSEMBLY ...................................50-110
METHOD FOR ASSEMBLING CENTER SWIVEL JOINT ASSEMBLY ......................................... 50-111
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY...................................................................50-112
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY ......................................................50-112
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY .....................................................50-115
REMOVE AND INSTALL MAIN PUMP ASSEMBLY .............................................................................50-118
METHOD FOR REMOVING MAIN PUMP ASSEMBLY .................................................................50-118
METHOD FOR INSTALLING MAIN PUMP ASSEMBLY................................................................50-120
REMOVE AND INSTALL ACCUMULATOR ASSEMBLY ......................................................................50-124
METHOD FOR REMOVING ACCUMULATOR ASSEMBLY (EU SPECIFICATION) ......................50-124
METHOD FOR REMOVING ACCUMULATOR ASSEMBLY (NORTH AMERICA SPECIFICATION, FOR
MACHINE WITH QUICK COUPLER) ........................................................................................50-125
METHOD FOR INSTALLING ACCUMULATOR ASSEMBLY (EU SPECIFICATION).....................50-127
METHOD FOR INSTALLING ACCUMULATOR ASSEMBLY (NORTH AMERICA SPECIFICATION,
FOR MACHINE WITH QUICK COUPLER) ................................................................................50-128
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY .............................50-130
METHOD FOR DISASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY ......................50-130
METHOD FOR ASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY ............................50-131
DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY .................................................50-133
METHOD FOR DISASSEMBLING TRAVEL PPC VALVE ASSEMBLY..........................................50-133
METHOD FOR ASSEMBLING TRAVEL PPC VALVE ASSEMBLY................................................50-134
WORK EQUIPMENT...................................................................................................................................50-136
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY ................................................................50-136
METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY ....................................................50-136
METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY...................................................50-137
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY...............................50-140
METHOD FOR DISASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY........................50-141
METHOD FOR ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY .............................50-144
CAB AND ITS ATTACHMENTS ..................................................................................................................50-149
REMOVE AND INSTALL OPERATOR'S CAB ASSEMBLY (CAB SPEC) .............................................50-149
METHOD FOR REMOVING OPERATOR'S CAB ASSEMBLY (CAB SPEC) .................................50-149
METHOD FOR INSTALLING OPERATOR'S CAB ASSEMBLY (CAB SPEC) ................................50-152
REMOVE AND INSTALL FLOOR FRAME ASSEMBLY (CANOPY SPEC)...........................................50-156
METHOD FOR REMOVING FLOOR FRAME ASSEMBLY (CANOPY SPEC)...............................50-156
METHOD FOR INSTALLING FLOOR FRAME ASSEMBLY (CANOPY SPEC) .............................50-159
REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS) ...........................................50-162
METHOD FOR REMOVING OPERATOR CAB GLASS (ADHERED GLASS)...............................50-163
METHOD FOR INSTALLING OPERATOR CAB GLASS (ADHERED GLASS)..............................50-164
REMOVE AND INSTALL FRONT WINDOW ASSEMBLY ....................................................................50-172
METHOD FOR REMOVING FRONT WINDOW ASSEMBLY ........................................................50-172
METHOD FOR INSTALLING FRONT WINDOW ASSEMBLY .......................................................50-173
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY ........................................................50-175
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY ............................................50-175
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY ...........................................50-179
REMOVE AND INSTALL OPERATOR'S SEAT ....................................................................................50-184
METHOD FOR REMOVING OPERATOR'S SEAT ........................................................................50-184
METHOD FOR INSTALLING OPERATOR'S SEAT .......................................................................50-184
REMOVE AND INSTALL SEAT BELT ..................................................................................................50-186

PC45MR-5, PC55MR-5 50-3

50 DISASSEMBLY AND ASSEM-
CONTENTS BLY

S/T
Steering
STRG
SIG Signal
SOL Solenoid
STD Standard
OPT
Option
OP
PRESS Pressure
SPEC Specification
SW Switch
TEMP Temperature
T/C Torque Converter
T/M Transmission

50-10 PC45MR-5, PC55MR-5

50 DISASSEMBLY AND ASSEM-
BLY HOW TO READ THIS MANUAL

RELATED INFORMATION ON DISASSEMBLY AND AS-

SEMBLY
HOW TO READ THIS MANUAL
This section describes the special tools, work procedures, and safety precautions necessary for removal, instal-
lation, disassembly, and assembly of the components and parts. In addition, tightening torques, quantity, and
weight of the coating materials, lubricants, and coolant necessary to these works are shown.
This shop manual does not include the descriptions of disassembling and assembling of the engine compo-
nents. For details, see the shop manual for the same model of the engine as the one which is mounted on the
machine.
Reading the special tools list
• The special tools required for removal and installation work are described in the list as symbols such as
A1, ..., X1. Part number, part name, necessity, and quantity are described.
• Details of the special tools are on “SPECIAL TOOLS LIST”. Details of sketches are on “SKETCHES OF
SPECIAL TOOLS”. Special tools required for a specified work is also described in each work procedures.
• The symbols used in the table of special tools indicate the following meanings.
■: Not substitutable, and work cannot be performed without the tool.
●: Very useful tools to use which can be substituted with commercially available tools.
Reading the work procedures
All the necessary information for the work procedure, the precautions and prior knowledge relating to the work
procedures is described step by step.
Reading the symbols
Important safety and quality portions are marked with the following symbols so that shop manual is used effec-
tively.
Symbol Item Remark
This signal indicates an extremely hazardous situation which will result in
Danger
death or serious injury if it is not avoided.
This signal indicates a potentially hazardous situation which will result in
Warning
death or serious injury if it is not avoided.
This signal indicates a potentially hazardous situation which will result in
Caution
injury or property damage around the machine if it is not avoided.
This signal indicates the weight of parts and components, and items which
Weight requires great attention to a selection of wires and working posture for
slinging work.
This signal indicates the tightening torque for portions which requires spe-
Tightening torque
cial care in assembling work.
This signal indicates a place to be coated with adhesive, grease, etc. in
Coat
assembling work.
This signal indicates a place to supply oil, coolant, etc. and the quantity.
Oil and coolant
(*1)

Draining This signal indicates a place to drain oil, coolant, etc. and the quantity.

This symbol indicates the works which require special caution for the ma-
Safety
chine safety when assembling.

*1:For places to supply oil, coolant, etc. and their quantities, see SPECIFICATIONS “TABLE OF FUEL, COOL-
ANT, AND LUBRICANTS”.

PC45MR-5, PC55MR-5 50-11

50 DISASSEMBLY AND ASSEM-
HOW TO READ THIS MANUAL BLY

Reading the signal word

Signal word for notice and remark describes the following.
Symbol Item Remark
If the precaution of this signal word is not observed, the machine damage
NOTICE NOTICE
or shortening of service life may occur.
REMARK Remarks This signal word contains useful information to know.

Reading the unit

International System of Units (SI) is used in this manual. For reference, units that have been used in the past
are given in { }.

50-12 PC45MR-5, PC55MR-5

50 DISASSEMBLY AND ASSEM-
BLY COATING MATERIALS LIST

COATING MATERIALS LIST

Coating materials which are not listed below, use the equivalent of products shown in this manual.

Adhesive
Komatsu code Part No. Capacity Container Main features and applications
• Use to prevent rubber gaskets, rubber
LT-1A 790-129-9030 150 g Tube
cushions, and cork plugs from falling off.
• Use for plastic (except polyethylene, pol-
20 g Polyethy- ypropylene, tetrafluoroethylene and vinyl
LT-1B 790-129-9050 (contained lene con- chloride), rubber, metal, and non-metal
2 pieces) tainer parts which require immediate and
strong adhesion.
• Features: Resistance to heat and chemi-
Polyethy- cals
LT-2 790-129-9180 50 g lene con-
tainer • Use to keep bolts and plugs from com-
ing loose and as sealant.
790-129-9060 Adhesive
Set of adhe- 1 kg • Use to bond and seal metal, glass and
LT-3 Pail
sive and hard- Hardener plastics.
ener 500 g
Polyethy-
LT-4 790-129-9040 250 g lene con- • Use to seal plugs for blank holes.
tainer
Holts • Heat-resistant seal used to repair en-
790-129-9120 75 g Tube
MH705 gines
• Instantaneous adhesive
THREEBOND Polyethy-
• Curing time: From 5 sec. to 3 min.
790-129-9140 50 g lene con-
1735 tainer • Use to bond mainly metals, rubbers,
plastics, and woods.
• Instantaneous adhesive

Aron Alpha Polyethy- • Quick-curing type (max. strength is ob-

790-129-9130 2 g lene contained after 30 minutes)
201 tainer • Use to bond rubbers, plastics, and met-
als.
• General-purpose instantaneous adhe-
sive with excellent resistance to heat
Loctite
428-99-80070 20 cc Tube and impact
499
• Use for the bushing mounting faces of
axle supports.

Polyethy- • Features: Resistance to heat and chemi-

Loctite
79A-129-9110 50 cc lene con- cals
648-50 tainer • Use to bond high-temperature fit parts.

PC45MR-5, PC55MR-5 50-13

50 DISASSEMBLY AND ASSEM-
COATING MATERIALS LIST BLY

Liquid gasket
Komatsu code Part No. Capacity Container Main features and applications
• Use to seal various threaded parts, pipe
Polyethy- joints, and flanges.
LG-5 790-129-9080 1 kg lene con-
tainer • Use to seal taper plugs, elbows, and nip-
ples for hydraulic piping.
• Features: Silicon-based heat and cold-
resistant
LG-6 790-129-9160 200 g Tube • Use to seal flange surface and threaded
parts
• Use to seal oil pan, final drive case, etc.
• Features: Silicon-based quick-curing
sealant
LG-7 790-129-9170 1 kg Tube • Use to seal flywheel housing, intake
manifold, oil pan, thermostat housing,
etc.
LG-8 • Features: Silicon-based heat, vibration,
THREEBOND 419-15-18131 100 g Tube and shock-resistant
1207B • Use to seal transfer case, etc.
• Use for rough surfaces such as the cir-
LG-9 cle gear top seal which is not clamped
THREEBOND 790-129-9310 200 g Tube by bolts, gaps in the weld which must be
1206D
caulked, etc.
• Can be coated with paint.
LG-10 • Use as lubricant or sealant when insert-
THREEBOND 790-129-9320 200 g Tube ing radiator hoses
1206E • Can be coated with paint.

LG-11 • Feature: Can be used together with solid

gaskets.
THREEBOND 790-129-9330 200 g Tube
• Use for covers of the transmission case
1121
and steering case etc.
THREEBOND
790-129-9090 100 g Tube • Liquid gasket used to repair engine
1211

Molybdenum disulfide lubricant

Komatsu code Part No. Capacity Container Main features and applications
• Use to prevent galling and seizure of
press-fitted parts, shrinkage-fitted parts,
LM-P — 200 g Tube and threaded parts.
• Use to lubricate linkages, bearings, etc.
• Spray type
• Thin molybdenum disulfide films are
made on metal surfaces to prevent the
LM-S — 190 g Pail
metals from galling.
• Use for the drive shaft splines, needle
bearings, various link pins, bolts, etc.

50-14 PC45MR-5, PC55MR-5

50 DISASSEMBLY AND ASSEM-
BLY COATING MATERIALS LIST

Seizure prevention compound

Komatsu code Part No. Capacity Container Main features and applications
• Feature: Seizure and galling prevention
compound with metallic super-fine-grain,
LC-G etc.
— — Pail
NEVER-SEEZ • Use for the mounting bolt in the high
temperature area of the exhaust mani-
fold and the turbocharger, etc.

Grease
Komatsu code Part No. Capacity Container Main features and applications
SYG2-400LI
SYG2-350LI
SYG2-400LI-A
G2-LI SYG2-160LI
• Lithium grease with extreme pressure lu-
G0-LI (*) SY- Various Various brication performance, general purpose
*: For cold dis- GA-160CNLI type.
tricts SYG0-400LI-A
(*)
SYG0-16CNLI
(*)
• Use for parts under heavy load.

Molybdenum Bellows-
• Caution: Do not use this grease for roll-
SYG2-400M 400 gx 10 ing bearings like swing circle bearings,
disulfide type con-
grease SYG2-400M-A 400 gx 20 tainer etc. and spline.
LM-G (G2-M) SYGA-16CNM 16 kg Pail • Caution: Use this grease for work equip-
ment pins only when installing them, but
do not use it afterwards.
Hyper white SYG2-400T-A
grease • Higher seizure resistance, heat resist-
SYG2-16CNT Bellows-
ance, and waterproof than molybdenum
G2-T SYG0-400T-A 400 g type con-
disulfide grease
G0-T(*) (*) 16 kg tainer
Pail
• Not so conspicuous on machine since
*: For cold dis- SYG0-16CNT color is white.
tricts (*)
Biogrease SYG2-400B
G2-B SYGA-16CNB
Bellows- • Since this grease is bacterially biode-
G2-BT (*) SYG2-400BT 400 g type con- gradable in short period, the impact on
*: For use at (*) tainer microorganisms, animals, and plants is
16 kg
high tempera- SY- Pail kept to the minimum.
ture and under GA-16CNBT
high load (*)
• Feature: Silicon-based grease with wider
G2-S operating temperature range and superi-
THREEBOND — 200 g Tube or thermal oxidative stability to prevent
1855
deterioration of rubber and plastic.
• Use for oil seals of the transmission, etc.

PC45MR-5, PC55MR-5 50-15

50 DISASSEMBLY AND ASSEM-
COATING MATERIALS LIST BLY

Komatsu code Part No. Capacity Container Main features and applications
• Feature: Urea (organic) grease with heat
resistance and long service life, inclu-
G2-U-SENS sion type.
427-12-11871 2 kg Pail
Grease • Use for rubber, bearing and oil seal in
damper.
• Caution: Do not mix with lithium grease.

Primer
Komatsu code Part No. Capacity Container Main features and applications
Loctite Glass con- • Use to accelerate hardening of instanta-
428-99-80080 100 mℓ
712 tainer neous adhesive.
SUNSTAR • Use as primer for cab side (Expira-
Glass con-

For adhered window glass

Paint Surface 22M-54–27260 150 mℓ tion date: 4 months after its produc-
tainer
Primer 435-98 tion date)
SUNSTAR • Use as primer for black ceramic-coat-
PRIMER ed glass surface and for hard poly-
22M-54-27240 150 mℓ Steel can
435-41 for carbonate-coated surface (Expiration
glass date: 6 days after its production date)
SUNSTAR • Use as primer for sash (alumite sur-
sash primer 22M-54-27250 900 mℓ Steel can face treatment) (Expiration date:6
GP-402 months after its production date)

Adhesive
Komatsu code Part No. Capacity Container Main features and applications
Polyethy- • Use as adhesive for glass (Expiration
For adhered window glass

Sika Japan Si-

20Y-54-39850 310 mℓ lene con- date: 6 months after its production
kaflex 256HV
tainer date)
SUNSTAR Ecocart • Use as adhesive for glass (Expiration
Penguin Super 22M-54-27210 320 mℓ (special date: 6 months after its production
560 container) date)
SUNSTAR Ecocart • Use as adhesive for glass (Expiration
Penguin Seal 416–926–6950 320 mℓ (special date: 6 months after its production
#560 container) date)

Caulking material
Komatsu code Part No. Capacity Container Main features and applications
SUNSTAR Polyethy- • Use to seal for joint between glasses
For adhered window glass

Penguin Seal 417-926-3920 320 mℓ lene con- (Expiration date: 4 months after its
No.2505 tainer production date)
Polyethy-
SEKISUI Sili- • Use to seal front window (Expiration
20Y-54-55130 333 mℓ lene con-
cone Sealant date: 6 months after its production)
tainer
GE TOSHIBA • Translucent white seal used for joint
SILICONES 22M-54-27220 333 mℓ Cartridge between glasses (Expiration date: 12
TOSSEAL381 months after its production date)

50-16 PC45MR-5, PC55MR-5

50 DISASSEMBLY AND ASSEM-
BLY SPECIAL TOOLS LIST

SPECIAL TOOLS LIST

How to read the tool list
• Part No.
Tools with part number 79*T-***-**** are not supplied (to be locally manufactured).
• Necessity:
■: Tools not substituted, must always be equipped.
●: Very useful tools which can be substituted with commercially available tools.
• New/Redesign:
N: Tools with new part numbers, newly developed for this model.
R: Tools, with advanced part numbers, developed by improving existing tools for other models.
Blank: Tools already available for other models that can be used without any modification.
• Sketch:
○: Tools marked with ○ in the sketch column have the sketches.
Sketches are introduced in “SKETCHES OF SPECIAL TOOLS”, and all sketches of “79*T-***-***”are descri-
bed.

Tools for removal and installation of supply pump assembly

New/Redesign
Necessity

Sketch
Q'ty
Symbol Part No. Part name Remarks

Commercially
A Puller ■ 1 Removal of gear
available

Tools for removal and installation of travel motor and final drive assembly
New/Redesign
Necessity

Sketch
Q'ty

Symbol Part No. Part name Remarks

Commercially
A Block ● 2
available Removal and installation of travel motor
Commercially and final drive assembly
B Lifting tool ● 1
available

Tools for removal and installation of swing motor and swing machinery assembly
New/Redesign
Necessity

Sketch
Q'ty

Symbol Part No. Part name Remarks

Commercially Removal of swing motor and swing ma-

A Forcing screw ■ 2
available chinery assembly

PC45MR-5, PC55MR-5 50-17

50 DISASSEMBLY AND ASSEM-
SPECIAL TOOLS LIST BLY

Tools for disassembly and assembly of swing machinery assembly

Tools for disassembly and assembly of track roller assembly

New/Redesign
Necessity

Sketch
Q'ty
Symbol Part No. Part name Remarks

790-101-5001 Push tool kit ■ 1

790-101-5081 Plate ■ 1
A Press-fit of bushing
790-101-5021 Grip ■ 1
01010-50816 Bolt ■ 1
B 791-430-3230 Installer ■ 1 Installation of floating seal

Tools for disassembly and assembly of carrier roller assembly

New/Redesign
Necessity

Sketch
Q'ty
Symbol Part No. Part name Remarks

790-101-5001 Push tool kit ■ 1

790-101-5081 Plate ■ 1
A Press-fit of bearing
790-101-5021 Grip ■ 1
01010-50816 Bolt ■ 1
790-101-5001 Push tool kit ■ 1
790-101-5111 Plate ■ 1
B Press-fit of dust seal
790-101-5021 Grip ■ 1
01010-50816 Bolt ■ 1

Tools for disassembly and assembly of center swivel joint assembly

New/Redesign
Necessity

Sketch
Q'ty

Symbol Part No. Part name Remarks

790-101-2501 Push puller ● 1

790-101-2510 Block 1
790-101-2520 Screw 1
791-112-1180 Nut 1
Disassembly and assembly of center
A 790-101-2540 Washer 1
swivel joint assembly
790-101-2630 Leg 2
790-101-2570 Plate 4
790-101-2560 Nut 2
790-101-2660 Adapter 2

PC45MR-5, PC55MR-5 50-19

50 DISASSEMBLY AND ASSEM-
SPECIAL TOOLS LIST BLY

Tools for removal and installation of main pump assembly

New/Redesign
Necessity

Sketch
Q'ty
Symbol Part No. Part name Remarks

Removal and installation of main pump

A 796T-13S-1010 Torque adapter ● 1 ○
assembly

Tools for disassembly and assembly of work equipment cylinder assembly

New/Redesign
Necessity

Sketch
Sym-

Q'ty
Part No. Part name Remarks
bol

790-502-1003 Cylinder repair stand ■ 1 Disassembly and assembly of hydraulic

A
790-101-1102 Hydraulic pump ■ 1 cylinder

Removal and installation of cylinder

B 790-330-1100 Wrench assembly ■ 1
head
Socket (width across
790-302-1270 ■ 1
flats50 mm)
Socket (width across
790-302-1280 ■ 1
flats55 mm)
Socket (width across
C 790-302-1470 ■ 1 Removal and installation of nut
flats55 mm long socket type)
Socket (width across
790-302-1310 ■ 1
flats65 mm)
Socket (width across
790-302-1320 ■ 1
flats65 mm long socket type)
790-201-1702 Push tool kit ■ 1
790-101-5021 • Grip 1
01010-50810 • Bolt 1
790-201-1731 • Push tool 1
D Press-fit of bushing
790-201-1741 • Push tool 1
790-201-1751 • Push tool 1
790-201-1761 • Push tool 1
790-201-1771 • Push tool 1

50-20 PC45MR-5, PC55MR-5

50 DISASSEMBLY AND ASSEM-
BLY SPECIAL TOOLS LIST

New/Redesign
Necessity

Sketch
Sym-

Q'ty
Part No. Part name Remarks
bol

790-201-1500 Push tool kit ■ 1

790-101-5021 • Grip 1
01010-50816 • Bolt 1
790-201-1540 • Plate 1
E Press-fit of dust seal
790-201-1550 • Plate 1
790-201-1560 • Plate 1
790-201-1570 • Plate 1
790-201-1580 • Plate 1
F 790-720-1000 Expander ● 1 Installation of piston ring
796-720-1620 Ring ● 1
07281-00609 Clamp ● 1
796-720-1640 Ring ● 1
07281-00909 Clamp ● 1
G Installation of piston ring
796-720-1650 Ring ● 1
07281-01029 Clamp ● 1
796-720-1670 Ring ● 1
07281-01279 Clamp ● 1

Tools for removal and installation of operator's cab glass (adhered glass)
New/Redesign
Necessity

Sketch
Q'ty

Symbol Part No. Part name Remarks

A 793-498-1210 Lifter (suction cup) ■ 2

Commercially
B Seal cutter ■ 1
available
Commercially
C Extra fine wire (piano wire, etc) ■ 1
available
Commercially
D Pliers ■ 1 Removal and installation of operator's
available
cab glass (adhered glass)
Commercially
E Cutter knife ■ 1
available
Commercially
F Scraper ■ 1
available
Commercially
G Caulking gun ■ 1
available

PC45MR-5, PC55MR-5 50-21

50 DISASSEMBLY AND ASSEM-
SKETCHES OF SPECIAL TOOLS BLY

SKETCHES OF SPECIAL TOOLS

k Komatsu does not take any responsibility for special tools manufactured according to these sketch-
es.
796T-126–1210: WRENCH

796T-13S–1010: TORQUE ADPTOR

50-22 PC45MR-5, PC55MR-5

50 DISASSEMBLY AND ASSEM-
BLY REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY

ENGINE AND COOLING SYSTEM

REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY

Air conditioner
compressor Supply pump
Counterweight Draining Cooling (machine with air assembly
conditioner only)

Tools for removal and installation of supply pump assembly

New/Redesign
Necessity

Sketch
Q'ty
Symbol Part No. Part name Remarks

Commercially
A Puller ■ 1 Removal of gear
available

METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY

Counterweight
1. Remove counterweight assembly. For details, see “REMOVE AND INSTALL COUNTERWEIGHT ASSEM-
BLY”.
Draining
2. Loosen drain valve (1), and drain coolant.

6 Radiator:
8.9 ℓ
REMARK
Check that coolant is completely drained, and then tighten
drain valve (1).

PC45MR-5, PC55MR-5 50-23

50 DISASSEMBLY AND ASSEM-
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY BLY

Cooling
3. Remove bolts (2) (5 pieces), and remove fan guard (3).
REMARK
For machine with air conditioner, 4 pieces of bolts (2) are
provided.

4. Remove clamp (4).

5. Loosen clamp (5) and (6), and remove hose (7).

Air conditioner compressor (machine with air conditioner only)

6. Remove bolts (8) (2 pieces), and remove guard (9).
7. Loosen bolt (10), and tighten bolt (11).
8. Loosen air conditioner compressor belt (12), and then re-
move air conditioner compressor belt (12).

9. Disconnect connector M12 (13).

10. Remove bolts (14) (2 pieces) and (15), and remove air
conditioner compressor assembly (16).

11. Remove bolts (17) (2 pieces), and remove bracket (18).

12. Remove bolts (19) (4 pieces), and remove idle pulley (20).
13. Remove bolts (21) (4 pieces), and remove bracket (22).

50-24 PC45MR-5, PC55MR-5

50 DISASSEMBLY AND ASSEM-
BLY REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY

Supply pump assembly

14. Disconnect hoses (23) and (24).
15. Remove clamp (25).
16. Remove bolts (26) (2 pieces), and move fuel element as-
sembly (27) aside so that it does not hinder the work.

17. Disconnect hose (28).

18. Disconnect connector (29).

19. Loosen sleeve nuts (30) and (31), and remove high-pres-
sure pipe (32).
20. Disconnect connector M14 (33).

21. Remove bolts (34) (4 pieces), and remove cover (35).

22. Put marks (a) between supply pump drive gear (36) and
idler gear (37).

PC45MR-5, PC55MR-5 50-25

50 DISASSEMBLY AND ASSEM-
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY BLY

23. Remove nut (38) and washer (39).

24. Remove supply pump drive gear (36) by using puller (A).

25. Remove bolts (40) (3 pieces), and remove supply pump

assembly (41).

METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY

Supply pump assembly
1. Install supply pump assembly (41) with bolts (40) (3
pieces).
REMARK
Apply lubricating oil to O-ring, and take care not to turn it
up when installing the assembly.
3 Bolt (40):
22.6 to 28.4 Nm {2.3 to 2.9 kgm}

2. Align marks (a) between supply pump drive gear (36) and
idler gear (37), and install supply pump drive gear (36).
3. Install washer (39) and nut (38).
3 Nut (38):
75 to 85 Nm {7.7 to 8.7 kgm}
REMARK
Check that marks (a) between supply pump drive gear (36)
and idler gear (37) are not misaligned.

50-26 PC45MR-5, PC55MR-5

50 DISASSEMBLY AND ASSEM-
BLY REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY

4. Install cover (35) with bolts (34) (4 pieces).

3 Bolt (34):
22.6 to 28.4 Nm {2.3 to 2.9 kgm}

5. Connect connector M14 (33).

6. Install high-pressure pipe (32) according to the following
procedure.
1) Apply fuel to the threaded portions of sleeve nuts (30)
and (31).
2) Fix high-pressure pipe (32) so that sleeve nuts (30)
and (31) can be rotated smoothly by hand.
3) Finger-tighten sleeve nuts (30) and (31) lightly.
4) Tighten sleeve nuts (30) and (31) to the specified tor-
que.
3 Sleeve nuts (30) and (31):
29.4 to 34.3 Nm {3.0 to 3.5 kgm}
7. Connect connector (29).
8. Connect hose (28).

9. Install fuel element assembly (27) with bolts (26) (2

pieces).
3 Bolt (26):
35 to 43 Nm {3.6 to 4.4 kgm}
10. Install clamp (25).
11. Connect hoses (23) and (24).

PC45MR-5, PC55MR-5 50-27

50 DISASSEMBLY AND ASSEM-
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY BLY

Air conditioner compressor (machine with air conditioner only)

12. Install bracket (22) with bolts (21) (4 pieces).
3 Bolt (21) on the engine mount side:
59 to 74 Nm {6.0 to 7.5 kgm}
13. Install idle pulley (20) with bolts (19) (4 pieces).
14. Install bracket (18) with bolts (17) (2 pieces).

15. Install air conditioner compressor assembly (16) with bolts

(14) (2 pieces) and (15).
16. Connect connector M12 (13).

17. Install air conditioner compressor belt (12).

18. Rotate bolt (11) in loosening direction, and adjust air condi-
tioner compressor belt (12).
REMARK
Adjust the air conditioner compressor belt tension. For de-
tails, see TESTING AND ADJUSTING, “TEST AND AD-
JUST AIR CONDITIONER COMPRESSOR BELT TEN-
SION”.
19. Tighten bolt (10).
20. Install guard (9) with bolts (8) (2 pieces).
Cooling
21. Fasten clamps (5) and (6) to install hose (7).
3 Clamp (5):
5.9±0.49 Nm {0.6±0.05 kgm}
3 Clamp (6):
4.4±0.49 Nm {0.45±0.05 kgm}
22. Install clamp (4).

50-28 PC45MR-5, PC55MR-5

50 DISASSEMBLY AND ASSEM-
BLY REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY

23. Install fan guard (3) with bolts (2) (4 pieces).

Counterweight assembly
24. Install the counterweight assembly. For details, see “REMOVE AND INSTALL COUNTERWEIGHT ASSEM-
BLY”.
Refilling radiator with coolant
25. Refill the radiator with coolant to the specified level through the coolant filler port. Run the engine to circu-
late the coolant, and then check the coolant level again.

5 Radiator:
8.9 ℓ

PC45MR-5, PC55MR-5 50-29

50 DISASSEMBLY AND ASSEM-
REMOVE AND INSTALL STARTER ASSEMBLY BLY

REMOVE AND INSTALL STARTER ASSEMBLY

METHOD FOR REMOVING STARTER ASSEMBLY

Floor
1. Open the floor. For details, see TESTING AND ADJUSTING, “METHOD FOR OPENING AND CLOSING
FLOOR”.
Starting motor assembly
2. Remove bolts (1) (2 pieces), and remove heat insulation
plate (2).

3. Remove clamp (3).

4. Disconnect terminals M5 (4) and M6 (5).

5. Remove bolts (6) (2 pieces), and remove starting motor

assembly (7).

50-30 PC45MR-5, PC55MR-5

50 DISASSEMBLY AND ASSEM-
BLY REMOVE AND INSTALL STARTER ASSEMBLY

METHOD FOR INSTALLING STARTER ASSEMBLY

Starting motor assembly
1. Install starting motor assembly (7) with bolts (6) (2 pieces).

2. Connect terminals M5 (4) and M6 (5).

3 Terminal M6 (5):
1.7 to 2.4 Nm {0.17 to 0.24 kgm}
3 Terminal M5 (4):
7.4 to 9.8 Nm {0.76 to 1.0 kgm}
3. Install clamp (3).

4. Install heat insulation cover (2) with bolts (1) (2 pieces).

Floor
5. Close the floor. For details, see TESTING AND ADJUSTING, “METHOD FOR OPENING AND CLOSING
FLOOR”.

PC45MR-5, PC55MR-5 50-31

50 DISASSEMBLY AND ASSEM-
REMOVE AND INSTALL RADIATOR ASSEMBLY BLY

REMOVE AND INSTALL RADIATOR ASSEMBLY

Air conditioner
condenser assembly Fuel cooler Radiator
Floor Draining (machine with air assembly assembly
conditioner only)

METHOD FOR REMOVING RADIATOR ASSEMBLY

Floor
1. Open the floor. For details, see TESTING AND ADJUSTING, “METHOD FOR OPENING AND CLOSING
FLOOR”.
Draining
2. Open cover (1).
NOTICE
Be sure to lock cover (1) when it has been opened.

3. Loosen drain valve (2), and drain coolant.

6 Radiator:
8.9 ℓ
REMARK
Check that coolant is completely drained, and then tighten
drain valve (2).

50-32 PC45MR-5, PC55MR-5

50 DISASSEMBLY AND ASSEM-
BLY REMOVE AND INSTALL RADIATOR ASSEMBLY

4. Remove bolts (10) (2 pieces).

5. Remove bolts (13) (2 pieces), and remove partition plate

(14).
6. Loosen clamp (15), and disconnect hose (16).

7. Remove clamp (17).

8. Disconnect hose (18).

9. Remove bolts (19) (3 pieces), and remove chamber (20).

Air conditioner condenser assembly (machine with air conditioner only)

10. Remove bolts (21) (2 pieces), and move receiver drier (22)
aside so that it does not hinder the work.

PC45MR-5, PC55MR-5 50-33

50 DISASSEMBLY AND ASSEM-
REMOVE AND INSTALL RADIATOR ASSEMBLY BLY

11. Remove bolts (23) (4 pieces), and move air conditioner

condenser assembly (25) so that it does not hinder the
work.

Fuel cooler assembly

12. Remove bolts (26a) (2 pieces), and remove fuel cooler as-
sembly (24).

Radiator assembly
13. Remove bolts (26) (2 pieces). (machine with air condition-
er only)

14. Remove bolts (27) (4 pieces), and remove cover (28).

15. Loosen clamp (29), and disconnect radiator lower hose

(30).

50-34 PC45MR-5, PC55MR-5

50 DISASSEMBLY AND ASSEM-
BLY REMOVE AND INSTALL RADIATOR ASSEMBLY

16. Move cover (12) sideways, loosen clamp (31), and discon-
nect radiator upper hose (32).

17. Remove bolts (33) (4 pieces), and remove bracket (34).

18. Remove radiator assembly (35).

METHOD FOR INSTALLING RADIATOR ASSEMBLY

Radiator assembly
1. Install radiator assembly (35).
REMARK
Check that convex portions (a) of radiator assembly (35) is
securely fitted in concave portions (b).
2. Install bracket (34) with bolts (33) (4 pieces).

3. Connect radiator upper hose (32), and fasten it with clamp

(31).
3 Clamp (31):
5.9±0.49 Nm {0.6±0.05 kgm}

PC45MR-5, PC55MR-5 50-35

50 DISASSEMBLY AND ASSEM-
REMOVE AND INSTALL RADIATOR ASSEMBLY BLY

4. Connect radiator lower hose (30), and fasten it with clamp

(29).
3 Clamp (29):
5.9±0.49 Nm {0.6±0.05 kgm}

5. Install cover (28) with bolts (27) (4 pieces).

6. Install bolts (26) (2 pieces). (machine with air conditioner

only)

Fuel cooler assembly

7. Install fuel cooler assembly (24) with bolts (23a) (2 pieces).

Air conditioner condenser assembly (machine with air conditioner only)

8. Install air conditioner condenser assembly (25) with bolts
(23) (4 pieces).

50-36 PC45MR-5, PC55MR-5

50 DISASSEMBLY AND ASSEM-
BLY REMOVE AND INSTALL RADIATOR ASSEMBLY

9. Install receiver drier (22) with bolts (21) (2 pieces).

Cover
10. Install chamber (20) with bolts (19) (3 pieces).

11. Connect hose (18).

12. Install clamp (17).

13. Connect hose (16), and fasten it with clamp (15).

14. Install partition plate (14) with bolts (13) (2 pieces).

15. Install cover (12) with bolts (10) (2 pieces).

PC45MR-5, PC55MR-5 50-37

50 DISASSEMBLY AND ASSEM-
REMOVE AND INSTALL RADIATOR ASSEMBLY BLY

16. Close cover (1).

Floor
17. Close the floor. For details, see TESTING AND ADJUSTING, “METHOD FOR OPENING AND CLOSING
FLOOR”.
Refilling radiator with coolant
18. Refill the radiator with coolant to the specified level through the coolant filler port. Run the engine to circu-
late the coolant, and then check the coolant level again.

5 Radiator:
8.9 ℓ

50-38 PC45MR-5, PC55MR-5

50 DISASSEMBLY AND ASSEM-
BLY REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY

REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY

Air conditioner Hydraulic oil

Draining Floor Cover condenser assembly cooler assembly,
(machine with air Fuel cooler
conditioner only) assembly

METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY

Draining
1. Release the remaining pressure in the hydraulic tank. For details, see TESTING AND ADJUSTING,
“METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC TANK”.
2. Remove bolts (1) (6 pieces), and remove cover (2).

3. Remove drain plug (3), and drain the hydraulic oil.

6 Hydraulic tank:
20 ℓ
REMARK
Check that hydraulic oil is completely drained, and then
tighten drain plug (3).

Floor
4. Open the floor. For details, see TESTING AND ADJUSTING, “METHOD FOR OPENING AND CLOSING
FLOOR”.

PC45MR-5, PC55MR-5 50-39

50 DISASSEMBLY AND ASSEM-
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY BLY

Cover
5. Open covers (4) and (5).
NOTICE
Be sure to lock the covers when they have been
opened.

6. Remove bolts (15) (2 pieces), and remove partition plate

(16).
7. Loosen clamp (17), and disconnect hose (18).

8. Remove clamp (19).

9. Remove clamps (20) (2 places).
10. Disconnect hose (21), and remove sub-tank (22).

11. Remove bolts (23) (3 pieces), and remove chamber (24).

(Except for the machines ready for installation of quick
coupler)

Pre-cleaner (for the machines ready for installation of quick coupler)

12. Remove the clamp (38), and remove the pre-cleaner (39).

50-40 PC45MR-5, PC55MR-5

50 DISASSEMBLY AND ASSEM-
BLY REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY

Air conditioner condenser assembly (machine with air conditioner only)

13. Remove bolts (25) (2 pieces), and move receiver drier (26)
aside so that it does not hinder the work.

14. Remove bolts (27) (4 pieces), and move air conditioner

condenser assembly (29) so that it does not hinder the
work.

Hydraulic oil cooler assembly, fuel cooler assembly

15. Remove bolts (27a) (2 pieces), and remove fuel cooler as-
sembly (28).

16. Remove clamp (30), and disconnect hose (31).

17. Remove bolts (32) (3 pieces), and remove bracket (33).

PC45MR-5, PC55MR-5 50-41

50 DISASSEMBLY AND ASSEM-
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY BLY

18. Disconnect hoses (34) and (35).

19. Remove bolts (36) (4 pieces), and remove oil cooler as-
sembly (37).

METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY

Oil cooler assembly
1. Install oil cooler assembly (37) with bolts (36) (4 pieces).

2. Connect hoses (34) and (35).

3. Install bracket (33) with bolts (32) (3 pieces).

50-42 PC45MR-5, PC55MR-5

50 DISASSEMBLY AND ASSEM-
BLY REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY

4. Connect hose (31), and install clamp (30).

Fuel cooler assembly

5. Install fuel cooler assembly (28) with bolts (27a) (2 pieces).

Air conditioner condenser assembly (machine with air conditioner only)

6. Install air conditioner condenser assembly (29) with bolts
(27) (4 pieces).

7. Install receiver drier (26) with bolts (25) (2 pieces). (ma-

chine with air conditioner only)

PC45MR-5, PC55MR-5 50-43

50 DISASSEMBLY AND ASSEM-
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY BLY

Cover
8. Install chamber (24) with bolts (23) (3 pieces). (Except for
the machines ready for installation of quick coupler)

9. Install the pre-cleaner (39), and install the clamp (38). (For
the machines ready for installation of quick coupler)
REMARK
Install it so that the water drain outlet faces downward.
3 Clamp (38):
6.8±0.49 Nm {0.7±0.05 kgm}

10. Connect hose (21), and install sub-tank (22).

11. Install clamps (20) (2 places).
12. Install clamp (19).

13. Connect hose (18), and fasten clamp (17).

14. Install partition plate (16) with bolts (15) (2 pieces).

15. Close covers (4) and (5).

50-44 PC45MR-5, PC55MR-5

50 DISASSEMBLY AND ASSEM-
BLY REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY

16. Tighten drain plug (3).

3 Drain plug (3):
58.8 to 78.4 Nm {6 to 8 kgm}

17. Install cover (2) with bolts (1) (6 pieces).

Floor
18. Close the floor. For details, see TESTING AND ADJUSTING, “METHOD FOR OPENING AND CLOSING
FLOOR”.
Refilling hydraulic tank with oil
19. Refill the hydraulic tank with Komatsu genuine oil to the specified level through the oil filler port. Start the
engine to circulate the oil through the piping, and check the oil level again.

5 Hydraulic tank:
20 ℓ
20. Bleed air from the hydraulic circuit. For details, see TESTING AND ADJUSTING, “Bleed air from each part”.

PC45MR-5, PC55MR-5 50-45

50 DISASSEMBLY AND ASSEM-
REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY BLY

REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY

Air conditioner Hydraulic oil

Draining Floor Cover condenser assembly cooler assembly,
(machine with air Fuel cooler
conditioner only) assembly

METHOD FOR REMOVING ENGINE AND MAIN PUMP ASSEMBLY

Counterweight
1. Remove counterweight assembly. For details, see “REMOVE AND INSTALL COUNTERWEIGHT ASSEM-
BLY”.
Hydraulic tank
2. Release the remaining pressure in the hydraulic tank. For details, see TESTING AND ADJUSTING, “RE-
LEASE REMAINING PRESSURE FROM HYDRAULIC TANK”.
Draining
3. Loosen drain valve (1), and drain coolant.

6 Radiator:
8.9 ℓ
REMARK
Check that coolant is completely drained, and then tighten
drain valve (1).

4. Remove bolts (2) (6 pieces), and remove cover (3).

50-46 PC45MR-5, PC55MR-5

50 DISASSEMBLY AND ASSEM-
BLY REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY

5. Remove drain plug (4), and drain the hydraulic oil.

6 Hydraulic tank:
20 ℓ
REMARK
Check that hydraulic oil is completely drained, and then
tighten drain plug (4).

Partition plate
6. Remove bolts (5) (2 pieces), and remove partition plate
(6).
7. Loosen clamp (7), and disconnect hose (8).

8. Remove bolts (9) (3 pieces), and remove partition plate

(10).

Belt
9. Remove bolts (11) (5 pieces), and remove fan guards (12)
(2 pieces).
REMARK
For machine with air conditioner, 4 pieces of bolts are pro-
vided.

PC45MR-5, PC55MR-5 50-47

50 DISASSEMBLY AND ASSEM-
REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY BLY

Air conditioner compressor (machine with air conditioner only)

10. Remove bolts (13) (2 pieces), and remove guard (14).
11. Loosen bolt (15), and tighten bolt (16).
12. Loosen air conditioner compressor belt (17), and then re-
move air conditioner compressor belt (17).

13. Disconnect connector M12 (18).

14. Remove bolts (19) (2 pieces) and (20), and remove air
conditioner compressor assembly (21).

15. Remove bolts (22) (2 pieces), and remove bracket (23).

16. Remove bolts (24) (4 pieces), and remove idle pulley (25).
17. Remove bolts (26) (4 pieces), and remove bracket (27).

18. Loosen bolt (28).

19. Loosen bolt (29).

20. Loosen nut (30) and bolt (31).
21. Loosen alternator belt (32), and then remove alternator
belt (32).

50-48 PC45MR-5, PC55MR-5

50 DISASSEMBLY AND ASSEM-
BLY REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY

Fan
22. Disconnect heater hoses (33) and (34). (machine with air
conditioner only)
23. Loosen clamps (35) and (36), and remove hose (37).

24. Remove clamp (38).

25. Loosen clamps (39) and (40), and remove hose (41).
26. Remove bolts (42) (5 pieces), and move shroud (43) clos-
er to the engine.

27. Remove bolts (44) (4 pieces), and remove fan (45).

28. Remove shroud (43).

Fuel hose
29. Remove clamps (46) (2 places).
30. Disconnect fuel hoses (47) and (48).

PC45MR-5, PC55MR-5 50-49

50 DISASSEMBLY AND ASSEM-
REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY BLY

Wiring harness
31. Cut cable ties (49) (2 places).
32. Disconnect connectors M25 (50), M27 (51), and M26 (52).

33. Disconnect connectors M23 (53), M12 (54), and M24 (55).
34. Disconnect connectors M14 (56) and M11 (57).

35. Remove clamp (58).

36. Disconnect connectors M34 (59), M31 (60), M32 (61), and
M33 (62).

37. Remove heat insulation plate (63).

38. Disconnect ground cable (64).

50-50 PC45MR-5, PC55MR-5

50 DISASSEMBLY AND ASSEM-
BLY REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY

39. Remove clamp (65).

40. Disconnect terminals M5 (66) and M6 (67).

41. Remove clamp (68).

42. Disconnect connector M10 (69) and terminal M2 (70).

Hydraulic hose
43. Disconnect hoses (71), (72) and (73).

44. Disconnect hoses (74) and (75).

45. Disconnect hoses (76) and (77).

PC45MR-5, PC55MR-5 50-51

50 DISASSEMBLY AND ASSEM-
REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY BLY

46. Remove bolts (78) (4 pieces), and disconnect suction hose

(79).

Engine and main pump assembly

47. Remove nuts (80) (4 places), and remove U-bolt.
48. Remove clamp (81), and remove exhaust pipe (82).

49. Remove mount nuts (83) (4 pieces), sling engine and main
pump assembly (84), and remove it.
REMARK
• Check that all the wirings and pipings are disconnect-
ed.
• Be careful not to interfere with the parts around it when
removing the assembly.

4 Engine and main pump assembly (84):

265 kg

METHOD FOR INSTALLING ENGINE AND MAIN PUMP ASSEMBLY

Engine and main pump assembly
1. Sling engine and main pump assembly (84), and set it on
the machine.
REMARK
Be careful not to interfere with the parts around it when in-
stalling the assembly.

4 Engine and main pump assembly:

265 kg
2. Sling the engine and main pump assembly, and hold it.
3. Install mount nuts (83) (4 pieces).
2 Mount nut (83):
Liquid adhesive (LT-2)
3 Mount nut (83):
59 to 74 Nm {6 to 7.5 kgm}

50-52 PC45MR-5, PC55MR-5

50 DISASSEMBLY AND ASSEM-
BLY REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY

4. Install exhaust pipe (82) with clamp (81).

5. Fix exhaust pipe (82) with nuts (80) (4 places) and U-bolt.

Hydraulic hose
6. Connect suction hose (79) with bolts (78) (4 pieces).

7. Connect hoses (76) and (77).

8. Connect hoses (74) and (75).

9. Connect hoses (73), (72) and (71).

PC45MR-5, PC55MR-5 50-53

50 DISASSEMBLY AND ASSEM-
REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY BLY

Wiring harness
10. Connect connector M10 (69) and terminal M2 (70).
3 Terminal M2 (70):
5.9 to 9.8 Nm {0.6 to 1.0 kgm}
11. Install clamps (68).

12. Connect terminals M5 (66) and M6 (67).

3 Terminal M6 (67):
1.7 to 2.4 Nm {0.17 to 0.24 kgm}
3 Terminal M5 (66):
7.4 to 9.8 Nm {0.76 to 1.0 kgm}
13. Install clamp (65).

14. Connect ground cable (64).

15. Install heat insulation plate (63).

16. Connect connectors M33 (62), M32 (61), M31 (60), and
M34 (59).
17. Install clamp (58).

50-54 PC45MR-5, PC55MR-5

50 DISASSEMBLY AND ASSEM-
BLY REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY

18. Connect connectors M14 (56) and M11 (57).

19. Connect connectors M23 (53), M12 (54), and M24 (55).

20. Connect connectors M25 (50), M27 (51), and M26 (52).
21. Install cable ties (49) (2 places).

Fuel hose
22. Connect fuel hoses (47) and (48).
23. Install clamps (46) (2 places).

Fan
24. Move shroud (43) closer to the engine.
25. Install fan (45) with bolts (44) (4 pieces).

26. Install shroud (43) with bolts (42) (5 pieces).

27. Install hose (41), and fasten it with clamps (39) and (40).
3 Clamp (39):
5.9±0.49 Nm {0.6±0.05 kgm}
3 Clamp (40):
4.4±0.49 Nm {0.45±0.05 kgm}
28. Install clamp (38).

PC45MR-5, PC55MR-5 50-55

50 DISASSEMBLY AND ASSEM-
REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY BLY

29. Install hose (37), and fasten it with clamps (35) and (36).
3 Clamp (35):
5.9±0.49 Nm {0.6±0.05 kgm}
3 Clamp (36):
4.4±0.49 Nm {0.45±0.05 kgm}
30. Connect heater hoses (33) and (34). (machine with air
conditioner only)

Belt
31. Set alternator belt (32).
32. Tighten bolt (31), and adjust alternator belt (32).
REMARK
“”Adjust the alternator belt tension. For details, see TEST-
ING AND ADJUSTING, “TEST AND ADJUST ALTERNA-
TOR BELT TENSION”.
33. Tighten nut (30) and bolt (29).

34. Tighten bolt (28).

Air conditioner compressor (machine with air conditioner only)

35. Install bracket (27) with bolts (26) (4 pieces).
3 Bolt (26) on the engine mount side:
59 to 74 Nm {6.0 to 7.5 kgm}
36. Install idle pulley (25) with bolts (24) (4 pieces).
37. Install bracket (23) with bolts (22) (2 pieces).

38. Install air conditioner compressor assembly (21) with bolts

(19) (2 pieces) and (20).
39. Connect connector M12 (18).

50-56 PC45MR-5, PC55MR-5

50 DISASSEMBLY AND ASSEM-
BLY REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY

40. Install air conditioner compressor belt (17).

41. Rotate bolt (16) in loosening direction, and adjust air con-
ditioner compressor belt (17).
REMARK
Adjust the air conditioner compressor belt tension. For de-
tails, see TESTING AND ADJUSTING, “TEST AND AD-
JUST AIR CONDITIONER COMPRESSOR BELT TEN-
SION”.
42. Tighten bolt (15).
43. Install guard (14) with bolts (13) (2 pieces).
Fan guard
44. Install fan guards (12) (2 pieces) with bolts (11) (5 pieces).
REMARK
For machine with air conditioner, 4 pieces of bolts (11) are
provided.

Partition plate
45. Install partition plate (10) with bolts (9) (3 pieces).

46. Connect hose (8), and fasten it with clamp (7).

47. Install partition plate (6) with bolts (5) (2 pieces).

PC45MR-5, PC55MR-5 50-57

50 DISASSEMBLY AND ASSEM-
REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY BLY

48. Tighten drain plug (4).

3 Drain plug (4):
58.8 to 78.4 Nm {6 to 8 kgm}

49. Install cover (3) with bolts (2) (6 pieces).

Counterweight
50. Install the counterweight assembly. For details, see “REMOVE AND INSTALL COUNTERWEIGHT ASSEM-
BLY”.
Refilling radiator with coolant
51. Refill the radiator with coolant to the specified level through the coolant filler port. Run the engine to circu-
late the coolant, and then check the coolant level again.

5 Radiator:
8.9 ℓ
Refilling hydraulic tank with oil
52. Refill the hydraulic tank with Komatsu genuine oil to the specified level through the oil filler port. Start the
engine to circulate the oil through the piping, and check the oil level again.

5 Hydraulic tank:
20 ℓ
Air bleeding
53. Bleed air from the hydraulic circuit. For details, see TESTING AND ADJUSTING, “Bleed air from each part”.

50-58 PC45MR-5, PC55MR-5

50 DISASSEMBLY AND ASSEM-
BLY REMOVE AND INSTALL FUEL TANK ASSEMBLY

REMOVE AND INSTALL FUEL TANK ASSEMBLY

METHOD FOR REMOVING FUEL TANK ASSEMBLY

Draining
1. Open covers (1) and (2).
NOTICE
Be sure to lock the covers when they have been
opened.

2. Open fuel drain valve (3), and drain fuel.

6 When filled up with fuel:

65 ℓ
REMARK
Check that fuel is completely drained, and then tighten
drain valve (3).

Cover
3. Open cover (4).

4. Remove pin (5).

5. Remove bolts (6) (4 pieces), and remove cover (4).

PC45MR-5, PC55MR-5 50-59

50 DISASSEMBLY AND ASSEM-
REMOVE AND INSTALL FUEL TANK ASSEMBLY BLY

6. Remove bolts (7) and (8).

7. Remove bolts (9) (3 pieces), and remove cover (10).

Fuel tank assembly

8. Remove bolts (11) (2 pieces), and remove tank and brack-
et assembly (12). (Cab specification machine)

9. Disconnect connector M6 (13).

10. Remove clamp (14).

11. Disconnect hoses (white) (15) and (black) (16).
12. Disconnect drain hose (17).

50-60 PC45MR-5, PC55MR-5

50 DISASSEMBLY AND ASSEM-
BLY REMOVE AND INSTALL FUEL TANK ASSEMBLY

13. Remove bolts (18) and (19) (2 pieces each), and remove
bands (20) (2 pieces).
14. Remove fuel tank assembly (21).

METHOD FOR INSTALLING FUEL TANK ASSEMBLY

Fuel tank assembly
1. Set fuel tank assembly (21) on the machine.
2. Install bands (20) (2 pieces) with bolts (19) and (18) (2
pieces each).

3. Connect drain hose (17).

4. Connect hoses (white) (15) and (black) (16).
5. Install clamp (14).

6. Connect connector M6 (13).

7. Install tank and bracket assembly (12) with bolts (11) (2

pieces). (Cab specification machine)

PC45MR-5, PC55MR-5 50-61

50 DISASSEMBLY AND ASSEM-
REMOVE AND INSTALL FUEL TANK ASSEMBLY BLY

Cover
8. Install cover (10) with bolts (7), (8) and (9) (3 pieces).

9. Install cover (4) with bolts (6) (4 pieces).

10. Install pin (5).

11. Close cover (4).

12. Close covers (2) and (1).

50-62 PC45MR-5, PC55MR-5

50 DISASSEMBLY AND ASSEM-
BLY REMOVE AND INSTALL FUEL TANK ASSEMBLY

Refilling fuel tank with fuel

13. Refill with fuel to the specified level through the fuel filler port.

6 When filled up with fuel:

65 ℓ
Testing fuel circuit for leakage
14. Check the fuel system for leakage. For details, see TESTING AND ADJUSTING, “TEST FUEL CIRCUIT
FOR LEAKAGE”.
Bleeding air from fuel circuit
15. Bleed air in the fuel system. For details, see TESTING AND ADJUSTING, “BLEED AIR FROM FUEL SYS-
TEM”.

PC45MR-5, PC55MR-5 50-63

50 DISASSEMBLY AND ASSEM-
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY BLY

DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY

NOTICE
Only precautions are described. For details, see Shop Manual, “ENGINE 86E-7 to 98E-7 SERIES”
k Place the machine on a level ground, lower the work equipment completely to the ground in a stable
posture, set the lock lever to LOCK position, and then stop the engine.
k Disconnect (-) terminal of the battery after 2 minutes or more of engine stop or after checking that
the system operation lamp goes off.
k Since KDPF assembly becomes extremely hot, take care not to get burn injury.
k If KDPF assembly is hot, wait until it has cooled down before starting any work.
k Check that no combustible material (dry leaves, twigs, etc.) is accumulated around KDPF assembly.
If any dusts or combustible materials are found, remove them.
k KDPF assembly is fragile against shock such as falling, handle with care, and do not reuse it if it is
damaged.
k Keep the record for each KDPF assembly unit to manage the service life, and never use KDPF ex-
ceeding its service life.
k After cleaning or replacing KDPF assembly, clean and degrease KDPF main unit and around it, start
the engine, and then check for oil leakage and soot attached.
k Wear anti-dust masks since soot, ash, mat material, and metallic powder accumulated in KDPF may
be inhaled when cleaning, replacing, and disposing KDPF assembly and KCSF.
k Observe the laws and regulations when disposing of harmful objects such as oil, filters, and mat ma-
terials, etc.

50-64 PC45MR-5, PC55MR-5

50 DISASSEMBLY AND ASSEM- REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEM-
BLY BLY

POWER TRAIN
REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY
Tools for removal and installation of travel motor and final drive assembly

New/Redesign
Necessity

Sketch
Q'ty
Symbol Part No. Part name Remarks

Commercially
A Block ● 2
available Removal and installation of travel motor
Commercially and final drive assembly
B Lifting tool ● 1
available

METHOD FOR REMOVING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY

Track shoe assembly
1. Separate the track shoe assembly. For details, see “SEPARATION AND CONNECTION OF TRACK AS-
SEMBLY”.
Sprocket
2. Set block (A) under the track frame.
3. Remove bolts (1) (12 pieces), and remove sprocket (2).

4. Remove bolts (3) (3 pieces), and remove cover (4).

PC45MR-5, PC55MR-5 50-65

REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEM- 50 DISASSEMBLY AND ASSEM-
BLY BLY

Hose
5. Disconnect hoses (5), (6), (7), and (8).

6. Remove adapters (9), (10), (11), and (12).

Travel motor and final drive assembly

7. Sling travel motor and final drive assembly (13) and hold it
by using lifting tool (B).

8. Remove bolts (14) (12 pieces), sling travel motor and final
drive assembly (13), and remove it.

4 Travel motor and final drive assembly (13):

56 kg

50-66 PC45MR-5, PC55MR-5

50 DISASSEMBLY AND ASSEM- REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEM-
BLY BLY

METHOD FOR INSTALLING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY

Travel motor and final drive assembly
1. Sling travel motor and final drive assembly (13) and set it
to the machine by using lifting tool (B).

4 Travel motor and final drive assembly (13):

56 kg

2. Install travel motor and final drive assembly (13) with

mounting bolts (14) (12 pieces).
3 Bolt (14):
156 to 198 Nm {16.0 to 20.0 kgm}

Hose
3. Install adapters (12), (11), (10), and (9).

4. Connect hoses (8), (7), (6), and (5).

PC45MR-5, PC55MR-5 50-67

REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEM- 50 DISASSEMBLY AND ASSEM-
BLY BLY

5. Install cover (4) with bolts (3) (3 pieces).

Sprocket
6. Install sprocket (2) with bolts (1) (12 pieces).
2 Threaded portion of bolt (1):
Adhesive (LT-2)
3 Bolt (1):
156 to 198 Nm {16.0 to 20.0 kgm}
7. Push up the machine body by using the work equipment
and blade.
8. Remove block (A) from under the track frame.

Track shoe assembly

9. Install the track shoe assembly. For details, see “SEPARATION AND CONNECTION OF TRACK ASSEM-
BLY”.
Air bleeding
10. Bleed air from the hydraulic circuit. For details, see TESTING AND ADJUSTING, “BLEED AIR FROM HY-
DRAULIC CIRCUIT”.
11. Bleed air from the travel motor. For details, see TESTING AND ADJUSTING, , “METHOD FOR RELEAS-
ING REMAINING PRESSURE FROM TRAVEL MOTOR CIRCUIT”.
Refilling with oil
12. Refill with oil to the specified level through the oil filler port. Run the engine to circulate the oil through the
piping, and check the oil level again.

50-68 PC45MR-5, PC55MR-5

50 DISASSEMBLY AND ASSEM- REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY
BLY ASSEMBLY

REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY ASSEM-

BLY
Tools for removal and installation of swing motor and swing machinery assembly

New/Redesign
Necessity

Sketch
Q'ty
Symbol Part No. Part name Remarks

Commercially Removal of swing motor and swing ma-

A Forcing screw ■ 2
available chinery assembly

METHOD FOR REMOVING SWING MOTOR AND SWING MACHINERY ASSEM-

BLY
Swing motor and swing machinery assembly
1. Remove the floor frame assembly. For details, see “REMOVE AND INSTALL FLOOR FRAME ASSEMBLY
(CANOPY SPEC)”.
REMARK
Remove the operator's cab assembly of the cab specification machine. For details, see “REMOVE AND IN-
STALL OPERATOR'S CAB ASSEMBLY (CAB SPEC)”.
2. Disconnect hoses (1) to (5).

3. Remove mounting bolts (7) (8 pieces), and remove the

swing machinery from the frame by using forcing screws
(A) (2 pieces).
4. Sling swing motor and swing machinery assembly (6), and
remove it.

4 Swing motor and swing machinery assembly:

45 kg

PC45MR-5, PC55MR-5 50-69

REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY 50 DISASSEMBLY AND ASSEM-
ASSEMBLY BLY

METHOD FOR INSTALLING SWING MOTOR AND SWING MACHINERY ASSEM-

BLY
Swing motor and swing machinery assembly
1. Sling swing motor and swing machinery assembly (6), and
install it.

4 Swing motor and swing machinery assembly (6):

45 kg
2. Install mounting bolts (7) (8 pieces).
3 Mounting bolt (7):
98 to 123 Nm {10 to 12.5 kgm}

3. Connect hoses (1) to (5).

4. Install the floor frame assembly. For details, see “REMOVE
AND INSTALL FLOOR FRAME ASSEMBLY (CANOPY
SPEC)”.
REMARK
Install the operator's cab assembly of the cab specification
machine. For details, see “REMOVE AND INSTALL OP-
ERATOR'S CAB ASSEMBLY (CAB SPEC)”.

Refilling hydraulic tank with oil

5. Refill the hydraulic tank with Komatsu genuine oil to the specified level through the oil filler port. Start the
engine to circulate the oil through the piping, and check the oil level again. (For details, see STRUCTURE
AND FUNCTION, “TABLE OF FUEL, COOLANT, AND LUBRICANTS”.)
Air bleeding
6. Bleed air. For details, see TESTING AND ADJUSTING, “BLEED AIR FROM HYDRAULIC CIRCUIT”.

50-70 PC45MR-5, PC55MR-5

50 DISASSEMBLY AND ASSEM-
BLY DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY

DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY

No.1 planetary No.2 planetary Pinion shaft,

Swing motor carrier,
assembly
No.1 sun gear No.2 sun gear
carrier bearing A
assembly assembly assembly

Swing
A machinery
case

Tools for disassembly and assembly of swing machinery assembly

New/Redesign
Necessity

Sketch
Q'ty
Symbol Part No. Part name Remarks

A 796T-126-1210 Wrench ■ 1 ○ Tightening of nut

METHOD FOR DISASSEMBLING SWING MACHINERY ASSEMBLY

REMARK
The drain plug is not provided. Prepare an oil pan, etc. and drain oil from the swing machinery case during the
disassembling work.

6 Swing machinery case:

Approximately 1.3 ℓ

PC45MR-5, PC55MR-5 50-71

50 DISASSEMBLY AND ASSEM-
DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY BLY

Swing motor assembly

1. Set the swing motor and swing machinery assembly on
block (G), and remove swing motor assembly (1).

No.1 sun gear

2. Remove No.1 sun gear (2).

No.1 planetary carrier, No.2 sun gear assembly

3. Remove No.1 planetary carrier and No.2 sun gear assem-
bly (3).
4. Remove snap ring (4), and remove thrust washer (5), No.1
planetary gear (6), needle bearing (7), spacer (8), and
thrust washer (9).
5. Remove snap ring (10), and remove No.1 planetary carrier
(11) from No.2 sun gear (10a).

No.2 planetary carrier assembly

6. Remove snap ring (12), and remove thrust washer (13),
No.2 planetary gear (14), needle bearing (15), spacer (16),
and thrust washer (17).

50-72 PC45MR-5, PC55MR-5

50 DISASSEMBLY AND ASSEM-
BLY DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY

7. Remove nut (18) by using wrench (A).

8. Remove No.2 planetary carrier and bearing assembly (19).

REMARK
Press the end surface of pinion shaft (24) by using the
press, etc.

9. Remove bearing (21) from No.2 planetary carrier (20).

Pinion shaft, bearing assembly

10. Remove bearing (25) and seal (26) from pinion shaft (24).

PC45MR-5, PC55MR-5 50-73

50 DISASSEMBLY AND ASSEM-
DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY BLY

Swing machinery case

11. Remove outer races (27), (28), and oil seal (29) from
swing machinery case (22).

METHOD FOR ASSEMBLING SWING MACHINERY ASSEMBLY

Swing machinery case
1. Press fit oil seal (29) to swing machinery case (22) until it
hits the end by using push tool (B).
REMARK
• Install the oil seal with its spring facing upward.
• Be careful not to allow liquid gasket to attach to the oil
seal lip and shaft sliding part.
2 Press-fitting surface of oil seal:
Liquid gasket (LG-6)

2. Press fit outer races (28) and (27) to the swing machinery
case by using push tools (C) and (D).
Push tool (C): Outer race (28)
Push tool (D): Outer race (27)
REMARK
The figure shows an example of outer race (28).

Pinion shaft, bearing assembly

3. Install seal (26) to pinion shaft (24).
2 Seal sliding surface:
Grease (G2-LI)
4. Press fit bearing (25) to pinion shaft (24) by using push
tool (E).
Press-fitting force: 7.3 to 19.7 kN {0.74 to 2.01 t}

50-74 PC45MR-5, PC55MR-5

50 DISASSEMBLY AND ASSEM-
BLY DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY

5. Set swing machinery case (22) on pinion shaft and bearing

assembly (23).
Seal grease (G2-LI) in 40 to 60 % of clearance (a) be-
tween the swing machinery case and bearing.
REMARK
Be careful not to damage the oil seal.

No.2 planetary carrier assembly

6. Press fit bearing (21) to No.2 planetary carrier (20) by us-
ing push tool (F).
Press-fitting force: 2.94 to 11.18 kN {0.3 to 1.14 t}

7. Set No.2 planetary carrier and bearing assembly (19) on

pinion shaft (24), and press fit it by using the press, etc.
REMARK
Press fit the case gradually while rotating it.
2 Spline:
Grease (G2-LI)
Press-fitting force: 4.90 to 18.8 kN {0.50 to 1.92 t}

8. Tighten nut (18) by using wrench (A).

2 Nut:
Liquid adhesive (LT-2)
3 Nut:
392 to 441 Nm {40 to 45 kgm}

PC45MR-5, PC55MR-5 50-75

50 DISASSEMBLY AND ASSEM-
DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY BLY

9. Measure the starting torque of pinion shaft (24) by using

wrench (A), and check that the measured value is within
the following range.
Starting torque: 13.2 Nm {1.35 kgm}

10. Install thrust washer (17), spacer (16), needle bearing (15),
No.2 planetary gear (14), thrust washer (13), and snap ring
(12).
REMARK
Check that there is no play of No.2 planetary gear.

No.1 planetary carrier, No.2 sun gear assembly

11. Install No.1 planetary carrier (11) to No.2 sun gear (10a),
and install snap ring (10).
12. Install thrust washer (9), spacer (8), needle bearing (7),
No.1 planetary gear (6), and thrust washer (5), and install
snap ring (4).
REMARK
Check that there is no play of No.1 planetary gear.

13. Install No.1 planetary carrier and No.2 sun gear assembly
(3).

No.1 sun gear

14. Install No.1 sun gear (2).
Refilling with oil
15. Refill the inside of machinery case with power train oil.

50-76 PC45MR-5, PC55MR-5

50 DISASSEMBLY AND ASSEM-
BLY DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY

5 Swing machinery case:

Approximately 1.3 ℓ (TO10)
Swing motor assembly
16. Fit the O-ring, and install swing motor assembly (1).
3 Mounting bolt:
98 to 123 Nm {10 to 12.5 kgm}

PC45MR-5, PC55MR-5 50-77

50 DISASSEMBLY AND ASSEM-
REMOVE AND INSTALL SWING CIRCLE ASSEMBLY BLY

REMOVE AND INSTALL SWING CIRCLE ASSEMBLY

METHOD FOR REMOVING SWING CIRCLE ASSEMBLY

Revolving frame assembly
1. Remove the revolving frame assembly. For details, see “REMOVE AND INSTALL REVOLVING FRAME
ASSEMBLY”.
Swing circle assembly
2. Remove mounting bolts (1) (24 pieces).
3. Sling swing circle assembly (2), and remove it.

4 Swing circle assembly (2):

65 kg

METHOD FOR INSTALLING SWING CIRCLE ASSEMBLY

Swing circle assembly
1. Sling swing circle assembly (2), and set it on the machine.

4 Swing circle assembly:

65 kg

2. Sling the swing circle assembly, and install it so that “S

mark” of inner ring soft zone (a) of the inner race and outer
race soft zone (b) come to the positions respectively
shown in the figure.
2 Inner race tooth surface:
Grease (G2-LI)
3. Install mounting bolts (1) (24 piece).
2 Mounting bolts (1):
Adhesive (LT-2)
3 Mounting bolt (1):
98 to 122.5 Nm {10 to 12.5 kgm}

50-78 PC45MR-5, PC55MR-5

50 DISASSEMBLY AND ASSEM-
BLY REMOVE AND INSTALL SWING CIRCLE ASSEMBLY

Revolving frame assembly

4. Install the revolving frame assembly. For details, see “REMOVE AND INSTALL REVOLVING FRAME AS-
SEMBLY”.

PC45MR-5, PC55MR-5 50-79

50 DISASSEMBLY AND ASSEM-
DISASSEMBLE AND ASSEMBLE RECOIL SPRING BLY

UNDERCARRIAGE AND FRAME

DISASSEMBLE AND ASSEMBLE RECOIL SPRING
Tools for disassembly and assembly of recoil spring assembly

New/Redesign
Necessity

Sketch
Q'ty
Symbol Part No. Part name Remarks

Disassembly and assembly of recoil

A 792-371-1400 Sleeve ■ 1
spring assembly

METHOD FOR DISASSEMBLING AND ASSEMBLING RECOIL SPRING

Piston
1. Remove valve (1).
2. Remove piston (2).

Recoil spring
3. Set the recoil spring on the press by using sleeve (A).
k Since the load at installation of the spring is large
and dangerous, set the recoil spring assembly se-
curely to the sleeve.
4. Apply oil pressure slowly to compress the spring, remove
screw (3), and remove nut (4).
REMARK
Compress the spring until the nut is loose.
• Rubber shoe specification
Load at installation of spring: 42.4 kN {4326 kg}
• Iron and road liner shoe specification
Load at installation of spring: 26.9 kN {2748 kg}

50-80 PC45MR-5, PC55MR-5

50 DISASSEMBLY AND ASSEM-
BLY DISASSEMBLE AND ASSEMBLE RECOIL SPRING

5. Release oil pressure slowly to extend the spring, and re-

move stopper (5) and spring (6) from cylinder assembly
(7).
Free height of spring: 302 mm

Cylinder
6. Remove snap ring (8), and remove spacer (9) from cylin-
der (10).
7. Remove dust seal (11).
8. Remove O-ring (12) and buffer ring (13).

METHOD FOR ASSEMNLING RECOIL SPRING ASSEMBLY

Cylinder
1. Install O-ring (12) and buffer ring (13) to cylinder (10).
2. Install dust seal (11).
3. Fit spacer (9), and fix it with snap ring (8).

Recoil spring
4. Assemble cylinder assembly (7), spring (6), and stopper
(5).

PC45MR-5, PC55MR-5 50-81

50 DISASSEMBLY AND ASSEM-
DISASSEMBLE AND ASSEMBLE RECOIL SPRING BLY

5. Set the recoil spring on the press by using sleeve (A).

k Since the load at installation of the spring is large
and dangerous, set the recoil spring assembly se-
curely to the sleeve.

6. Apply oil pressure slowly to compress the spring, fit nut

(4), and install screw (3).
• Rubber shoe specification
Installed height of spring: 202.2 mm
Load at installation of spring: 42.4 kN {4326 kg}
• Iron and road liner shoe specification
Installed height of spring: 238.2 mm
Load at installation of spring: 26.9 kN {2748 kg}
REMARK
After assembling the recoil spring, check that the parallel-
ism of surface (a) of cylinder (7) and surface (b) of stopper
(5) is 0.5 mm or less.
Piston
7. Tighten plug (1) lightly.
REMARK
Tighten the plug temporarily and then return it by approxi-
mately 2 turns to discharge grease from grease hole (c).
8. Fill the cylinder with approximately 120 cc of grease (G2-
LI).
9. Install cylinder (2), and press it until grease comes out
from grease hole (c).
10. Tighten valve (1).
REMARK
After tightening the valve, check that the grease fitting
faces the outside of the machine (sideways).

50-82 PC45MR-5, PC55MR-5

50 DISASSEMBLY AND ASSEM-
BLY SEPARATION AND CONNECTION OF TRACK ASSEMBLY

SEPARATION AND CONNECTION OF TRACK ASSEMBLY

METHOD FOR SEPARATING TRACK ASSEMBLY
Track shoe
1. Rotate upper structure by 180 °, and lift the machine by using the work equipment and blade.
2. Loosen valve (1), remove the grease, and loosen the track
shoe tension.
k Do not loosen valve (1) by more than one turn, be-
cause the valve may fly out due to the high internal
pressure of the grease.

3. Sling track shoe assembly (2), and pull it backward to re-

move it.

4 Rubber shoe:
190 kg

4 Double grouser shoe:

290 kg

4 Triple shoe:
240 kg

4 Road liner:
290 kg

METHOD FOR INSTALLING TRACK ASSEMBLY

Track shoe
1. Sling track shoe assembly (2), and install it.

4 Rubber shoe:
190 kg

4 Double grouser shoe:

290 kg

4 Triple shoe:
240 kg

4 Road liner:
290 kg

PC45MR-5, PC55MR-5 50-83

50 DISASSEMBLY AND ASSEM-
SEPARATION AND CONNECTION OF TRACK ASSEMBLY BLY

2. Tighten valve (1), grease the track shoe, and adjust the
track shoe tension.
REMARK
Adjust the track shoe tension. For details, see TESTING
AND ADJUSTING, “TEST AND ADJUST TRACK TEN-
SION”.

50-84 PC45MR-5, PC55MR-5

50 DISASSEMBLY AND ASSEM-
BLY DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY

DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY

Tools for disassembly and assembly of idler assembly

New/Redesign
Necessity

Sketch
Q'ty
Symbol Part No. Part name Remarks

790-101-5001 Push tool kit ■ 1

790-101-5081 Plate ■ 1
A Press-fit of idler
790-101-5021 Grip ■ 1
01010-50816 Bolt ■ 1
B 791-430-3230 Installer ■ 1 Installation of floating seal

METHOD FOR DISASSEMBLING IDLER ASSEMBLY

Idler, support, shaft assembly
1. Remove cover (1).
2. Remove bracket (2).
3. Remove support (3).
4. Drain engine oil from the idler.

6 Inside of idler:
Approximately 20 cc
5. Remove the idler from support and shaft assembly (4).

6. Remove O-ring, shaft (5), and support (6).

PC45MR-5, PC55MR-5 50-85

50 DISASSEMBLY AND ASSEM-
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY BLY

Floating seal
7. Remove floating seal (7) of supports (3) and (6).
REMARK
• Clean, completely degrease and dry O-ring and the
contacting surfaces of O-rings.
• Apply engine oil (EO30-CD) to the sliding surface of
the floating seal, and take care that dust does not stick
to it.

Idler
8. Remove floating seals (8) (2 pieces) of idler (9).
REMARK
• Clean, completely degrease and dry O-ring and the
contacting surfaces of O-rings.
• Apply engine oil (EO30-CD) to the sliding surface of
the floating seal, and take care that dust does not stick
to it.

9. Remove bushings (10) (2 pieces) from idler (9).

METHOD FOR ASSEMBLING IDLER ASSEMBLY

Idler
1. Press fit bushings (10) (2 pieces) to idler (9) by using push
tool (A).

50-86 PC45MR-5, PC55MR-5

50 DISASSEMBLY AND ASSEM-
BLY DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY

2. Install floating seals (8) (2 pieces) to idler (9) by using in-

staller (B).
REMARK
• Clean, completely degrease and dry O-ring and the
contacting surfaces of O-rings.
• Apply engine oil (EO30-CD) to the sliding surface of
the floating seal, and take care that dust does not stick
to it.

Floating seal
3. Install floating seal (7) to supports (3) and (6) by using in-
staller (B).
REMARK
• Clean, completely degrease and dry O-ring and the
contacting surfaces of O-rings.
• Apply engine oil (EO30-CD) to the sliding surface of
the floating seal, and take care that dust does not stick
to it.

Idler, support, shaft assembly

4. Fit O-ring, and install shaft (5) to support (6).

5. Install support and shaft assembly (4) to the idler.

6. Refill the inside of idler with engine oil.

5 Inside of idler:
Approximately 20 cc (EO30-CD)
7. Install support (3).
2 Mounting bolt:
Liquid adhesive (LT-2)
8. Install bracket (2).
2 Mounting bolt:
Liquid adhesive (LT-2)
3 Mounting bolt:
98 to 123 Nm {10.0 to 12.5 kgm}
9. Install cover (1).

PC45MR-5, PC55MR-5 50-87

50 DISASSEMBLY AND ASSEM-
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY BLY

DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY

Tools for disassembly and assembly of track roller assembly

New/Redesign
Necessity

Sketch
Q'ty
Symbol Part No. Part name Remarks

790-101-5001 Push tool kit ■ 1

790-101-5081 Plate ■ 1
A Press-fit of bushing
790-101-5021 Grip ■ 1
01010-50816 Bolt ■ 1
B 791-430-3230 Installer ■ 1 Installation of floating seal

METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY

Collar
1. Remove snap ring and collar (1).
2. Drain engine oil from the roller.

6 Engine oil:
Approximately 135 cc
3. Remove snap ring and collar (2).

Shaft
4. Remove O-ring and shaft (3) from the roller.
Floating seal
5. Remove floating seal (4) from collars (1) and (2).
REMARK
• Clean, completely degrease and dry O-ring and the
contacting surfaces of O-rings.
• Apply engine oil (EO30-CD) to the sliding surface of
the floating seal, and take care that dust does not stick
to it.

50-88 PC45MR-5, PC55MR-5

50 DISASSEMBLY AND ASSEM-
BLY DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY

6. Remove floating seals (5) (2 pieces) from roller (6).

REMARK
• Clean, completely degrease and dry O-ring and the
contacting surfaces of O-rings.
• Apply engine oil (EO30-CD) to the sliding surface of
the floating seal, and take care that dust does not stick
to it.

Bushing
7. Remove bushings (7) (2 pieces) from roller (6).

METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY

Bushing
1. Press fit bushings (7) (2 pieces) to roller (6) by using push
tool (A).

Floating seal
2. Install floating seals (5) (2 pieces) to roller (6) by using in-
staller (B).
REMARK
• Clean, completely degrease and dry O-ring and the
contacting surfaces of O-rings.
• Apply engine oil (EO30-CD) to the sliding surface of
the floating seal, and take care that dust does not stick
to it.

PC45MR-5, PC55MR-5 50-89

50 DISASSEMBLY AND ASSEM-
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY BLY

3. Install floating seal (4) to collars (1) and (2) by using instal-
ler (B).
REMARK
• Clean, completely degrease and dry O-ring and the
contacting surfaces of O-rings.
• Apply engine oil (EO30-CD) to the sliding surface of
the floating seal, and take care that dust does not stick
to it.

Shaft
4. Fit O-ring, and install shaft (3) to the roller.

Collar
5. Fit collar (2), and fix it with the snap ring.
6. Refill the inside of roller with engine oil.

5 Inside of roller:
Approximately 135 cc (EO30-CD)
7. Fit collar (1), and fix it with the snap ring.

50-90 PC45MR-5, PC55MR-5

50 DISASSEMBLY AND ASSEM-
BLY DISASSEMBLEAND ASSEMBLE CARRIER ROLLER ASSEMBLY

DISASSEMBLEAND ASSEMBLE CARRIER ROLLER ASSEMBLY

Tools for disassembly and assembly of carrier roller assembly

New/Redesign
Necessity

Sketch
Q'ty
Symbol Part No. Part name Remarks

790-101-5001 Push tool kit ■ 1

METHOD FOR DISASSEMBLING CARRIER ROLLER ASSEMBLY

1. Remove cap (1).

2. Remove snap ring (2).

3. Remove shaft (3) from the roller.
4. Drain oil from the roller.

6 Inside of roller:
Approximately 30 cc

PC45MR-5, PC55MR-5 50-91

50 DISASSEMBLY AND ASSEM-
DISASSEMBLEAND ASSEMBLE CARRIER ROLLER ASSEMBLY BLY

5. Remove dust seal (4) from roller (5).

6. Remove ball bearings (6) (2 pieces) from roller (5).

METHOD FOR ASSEMBLING CARRIER ROLLER ASSEMBLY

1. Press fit ball bearings (6) (2 pieces) to roller (5) by using
push tool (A).
2 Bearing ball:
Grease (Showa Shell Sekiyu, Alvania EP-2 or
equivalent)

2. Press fit dust seal (4) to roller (5) by using push tool (B).
3. Seal grease in the roller.
2 Inside of roller:
Grease (Showa Shell Sekiyu, Alvania EP-2 or
equivalent)
Quantity of grease: Approximately 30 cc

50-92 PC45MR-5, PC55MR-5

50 DISASSEMBLY AND ASSEM-
BLY DISASSEMBLEAND ASSEMBLE CARRIER ROLLER ASSEMBLY

4. Install shaft (3) to the roller.

5. Install snap ring (2).
REMARK
Install the snap ring with the inside edge facing the shaft
end side.

6. Press fit cap (1) by using push tool (A).

Cap press-fitting depth (a): 10 mm

PC45MR-5, PC55MR-5 50-93

50 DISASSEMBLY AND ASSEM-
REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY BLY

REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY

METHOD FOR REMOVING REVOLVING FRAME ASSEMBLY

Work equipment assembly
1. Remove the work equipment assembly. For details, see “REMOVE AND INSTALL WORK EQUIPMENT
ASSEMBLY”.
2. Remove the floor frame assembly. For details, see “REMOVE AND INSTALL FLOOR FRAME ASSEMBLY
(CANOPY SPEC)”.
REMARK
Remove the operator's cab assembly of the cab specification machine. For details, see “REMOVE AND IN-
STALL OPERATOR'S CAB ASSEMBLY (CAB SPEC)”.
Boom cylinder assembly
3. Pull out pin (1), sling boom cylinder assembly (2), and re-
move it.

4 Boom cylinder:
45 kg

Center swivel joint

4. Disconnect hoses (3) to (11) from the center swivel joint,
and remove lever (12).

50-94 PC45MR-5, PC55MR-5

50 DISASSEMBLY AND ASSEM-
BLY REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY

Revolving frame assembly

5. Sling the revolving frame assembly, hold it, and remove
mounting bolt (13).
REMARK
Leave mounting bolts approximately 2 pieces each on the
front and rear side.

6. Remove the remaining mounting bolts, sling revolving

frame assembly (14), and remove it.
REMARK
• Remove remaining mounting bolts (13) while keeping a
balance in all directions of the assembly by using a lev-
er block, etc.
• Check that all the pipings are disconnected, and re-
move the center swivel joint while taking care not to
damage it.

4 Revolving frame assembly:

2250 kg

METHOD FOR INSTALLING REVOLVING FRAME ASSEMBLY

Revolving frame assembly
1. Sling revolving frame assembly (14), and set it on the ma-
chine.
REMARK
Be careful not to damage the center swivel joint when in-
stalling it.

4 Revolving frame assembly:

2250 kg

2. Sling the revolving frame assembly, hold it, and install it

with mounting bolt (13).
2 Revolving frame assembly mounting bolt:
Liquid adhesive (LT-2)
3 Revolving frame assembly mounting bolt:
117.6 to 137.2 Nm {12 to 14 kgm}

PC45MR-5, PC55MR-5 50-95

50 DISASSEMBLY AND ASSEM-
REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY BLY

Center swivel joint

3. Install lever (11), and connect hoses (3) to (10) to the cen-
ter swivel joint.
2 Lever mounting bolt:
Liquid adhesive (LT-2)
3 Lever mounting bolt:
98 to 123 Nm {10 to 12.5 kgm}

Boom cylinder assembly

4. Sling boom cylinder assembly (2), hold it, and insert pin
(1).
k Never insert your finger into the pin hole when
aligning pin hole position.

4 Boom cylinder:
45 kg
2 Sliding surface on the pin and swing bracket side:
Molybdenum disulfide lubricant (LM-P)
2 Greasing after installation:
Hyper white grease (G2-T)
5. Install the floor frame assembly. For details, see “REMOVE AND INSTALL FLOOR FRAME ASSEMBLY
(CANOPY SPEC)”.
REMARK
Install the operator's cab assembly of the cab specification machine. For details, see “REMOVE AND IN-
STALL OPERATOR'S CAB ASSEMBLY (CAB SPEC)”.
Work equipment assembly
6. Install the work equipment assembly. For details, see “REMOVE AND INSTALL WORK EQUIPMENT AS-
SEMBLY”.
Refilling hydraulic tank with oil
7. Refill the hydraulic tank with Komatsu genuine oil to the specified level through the oil filler port. Start the
engine to circulate the oil through the piping, and check the oil level again.
Air bleeding
8. Bleed air. For details, see TESTING AND ADJUSTING, “BLEED AIR FROM FUEL SYSTEM”.

50-96 PC45MR-5, PC55MR-5

50 DISASSEMBLY AND ASSEM-
BLY REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY

REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY

METHOD FOR REMOVING COUNTERWEIGHT ASSEMBLY

Floor
1. Open the floor. For details, see TESTING AND ADJUSTING, “METHOD FOR OPENING AND CLOSING
FLOOR”.
Cover
2. Remove bolts (1) and (2) (4 pieces) and bolts (2a) (2
pieces), and remove cover (3).

3. Open covers (4) and (5).

NOTICE
Be sure to lock the covers when they have been
opened.

4. Remove pin (6).

5. Remove bolts (7) (4 pieces), and remove cover (5).

6. Remove bolts (8) and (9).

PC45MR-5, PC55MR-5 50-97

50 DISASSEMBLY AND ASSEM-
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY BLY

7. Remove bolts (10) (3 pieces), and remove cover (11).

8. Remove bolts (12) (2 pieces).

9. Remove bolts (13) (2 pieces), and remove cover (14).

Air cleaner assembly

10. Loosen clamp (15).

11. Loosen clamp (16).

12. Remove bolts (17) (2 pieces), and remove air cleaner as-
sembly (18).

50-98 PC45MR-5, PC55MR-5

50 DISASSEMBLY AND ASSEM-
BLY REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY

13. Remove clamp (19).

Counterweight assembly
14. Remove bolt (20), and move bracket (21) aside so that it
does not hinder the work. (machine with air conditioner on-
ly)

15. Remove bolts (22) (2 pieces) and move bracket (23) aside
so that it does not hinder the work.

16. Remove bolts (24) (2 pieces), and remove cover (25).

17. Remove bolts (26) (4 pieces), sling bracket (27), and re-
move it.

4 Bracket (27):
70 kg

PC45MR-5, PC55MR-5 50-99

50 DISASSEMBLY AND ASSEM-
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY BLY

18. Sling additional counterweight (29), and hold it. (machine

with additional counterweight only)
19. Remove bolts (28) (2 pieces), sling additional counter-
weight (29), and remove it.

4 Additional counterweight (29):

250 kg

20. Sling counterweight assembly (31), and hold it.

21. Remove bolts (30) (4 pieces), sling counterweight assem-
bly (31), and remove it.
REMARK
Sling the assembly while sliding it rearward horizontally to
prevent it from interfering with the machine body.

4 Counterweight assembly (31):

650 kg

METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY

Counterweight assembly
1. Sling counterweight assembly (31), and set it on the ma-
chine.
REMARK
Lower the assembly while sliding it forward horizontally to
prevent it from interfering with the machine body.

4 Counterweight assembly (31):

650 kg
2. Install counterweight assembly (31) with bolts (30) (4
pieces).
2 Bolt (30):
Liquid adhesive (LT-2)
3 Bolt (30):
785 to 980 Nm {80 to 100 kgm}
3. Install additional counterweight (29) with bolts (28) (2
pieces). (machine with additional counterweight only)

4 Additional counterweight (29):

250 kg
3 Bolt (28):
455 to 565 Nm {46.5 to 58 kgm}

50-100 PC45MR-5, PC55MR-5

50 DISASSEMBLY AND ASSEM-
BLY REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY

4. Sling bracket (27), and install it with bolts (26) (4 pieces).

4 Bracket (27):
70 kg
2 Bolt (26):
Liquid adhesive (LT-2)
3 Bolt (26):
785 to 980 Nm {80 to 100 kgm}

5. Install cover (25) with bolts (24) (2 pieces).

6. Install bracket (23) with bolts (22) (2 pieces).

7. Install bracket (21) with bolt (20). (machine with air condi-
tioner only)

Air cleaner assembly

8. Install clamp (19).

PC45MR-5, PC55MR-5 50-101

50 DISASSEMBLY AND ASSEM-
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY BLY

9. Install air cleaner assembly (18) with bolts (17) (2 pieces).

10. Fasten clamp (16).
3 Clamp (16):
5.9±0.49 Nm {0.6±0.05 kgm}

11. Fasten clamp (15).

3 Clamp (15):
5.9±0.49 Nm {0.6±0.05 kgm}

Cover
12. Install cover (14) with bolts (12) and (13) (2 pieces each).

50-102 PC45MR-5, PC55MR-5

50 DISASSEMBLY AND ASSEM-
BLY REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY

13. Install cover (11) with bolts (8), (9) and (10) (3 pieces).

14. Install cover (5) with bolts (7) (4 pieces).

15. Install pin (6).

16. Close covers (4) and (5).

17. Install cover (3) with bolts (1) and (2) (4 pieces) and bolts
(2a) (2 pieces).

PC45MR-5, PC55MR-5 50-103

50 DISASSEMBLY AND ASSEM-
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY BLY

Floor
18. Close the floor. For details, see TESTING AND ADJUSTING, “METHOD FOR OPENING AND CLOSING
FLOOR”.

50-104 PC45MR-5, PC55MR-5

50 DISASSEMBLY AND ASSEM-
BLY REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY

HYDRAULIC SYSTEM
REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY
k Place the machine on a level ground, and lower the work equipment to the ground in a stable pos-
ture.
k Set the lock lever to LOCK position.
k Disconnect (-) terminal of the battery after 2 minutes or more of engine stop or after checking that
the system operation lamp goes off.
k Release the remaining pressure in the hydraulic circuit. For details, see TESTING AND ADJUSTING,
“RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM”.

METHOD FOR REMOVING CENTER SWIVEL JOINT ASSEMBLY

Hydraulic tank
1. Release the remaining pressure in the hydraulic tank. For details, see TESTING AND ADJUSTING,
“METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC TANK”.
Floor frame
2. Open the floor frame. For details, see TESTING AND ADJUSTING, “METHOD FOR OPENING AND
CLOSING FLOOR”.
3. Remove bolts (1) (4 pieces) and bolts (1a) (2 pieces), and
remove cover (2).

4. Loosen mounting bolt (2), and slide cover (3).

Center swivel joint assembly

5. Disconnect hoses (3) to (11).
6. Remove lever (12) from the center swivel joint.

PC45MR-5, PC55MR-5 50-105

50 DISASSEMBLY AND ASSEM-
REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY BLY

7. Disconnect hoses (13) to (20).

8. Disconnect hoses (21) and (22).

9. Remove elbow (23).
10. Remove mounting bolt (24), and remove the center swivel
joint assembly.

METHOD FOR INSTALLING CENTER SWIVEL JOINT ASSEMBLY

Center swivel joint assembly
1. Install the center swivel joint assembly with mounting bolt (24).
3 Mounting bolt (24):
39.2 to 49 Nm {4 to 5 kgm}
2. Install elbow (23).
3. Connect hoses (21) and (22).

50-106 PC45MR-5, PC55MR-5

50 DISASSEMBLY AND ASSEM-
BLY REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY

4. Connect hoses (13) to (20).

5. Install lever (12) to the center swivel joint.

2 Lever mounting bolt:
Liquid adhesive (LT-2)
3 Lever mounting bolt:
153 to 190 Nm {15.5 to 19.5 kgm}
6. Connect hoses (3) to (11).

7. Install cover (3) with mounting bolt (2).

8. Install cover (2) with bolts (1) (4 pieces) and bolts (1a) (2
pieces).
9. Close the floor frame. For details, see TESTING AND AD-
JUSTING, “METHOD FOR OPENING AND CLOSING
FLOOR”.

PC45MR-5, PC55MR-5 50-107

50 DISASSEMBLY AND ASSEM-
REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY BLY

Refilling hydraulic tank with oil

10. Refill the hydraulic tank with Komatsu genuine oil to the specified level through the oil filler port. Start the
engine to circulate the oil through the piping, and check the oil level again.
Air bleeding
11. Bleed air. For details, see TESTING AND ADJUSTING, “BLEED AIR FROM FUEL SYSTEM”.

50-108 PC45MR-5, PC55MR-5

50 DISASSEMBLY AND ASSEM- DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEM-
BLY BLY

DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY

Tools for disassembly and assembly of center swivel joint assembly

New/Redesign
Necessity

Sketch
Q'ty
Symbol Part No. Part name Remarks

790-101-2501 Push puller ● 1

PC45MR-5, PC55MR-5 50-109

DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEM- 50 DISASSEMBLY AND ASSEM-
BLY BLY

METHOD FOR DISASSEMBLING CENTER SWIVEL JOINT ASSEMBLY

Center swivel joint assembly
1. Remove bolt (1), and remove plate (2).
2. Remove O-ring (3) and snap ring (4).

3. Remove rotor (9) from swivel joint (5) by using push puller
(A).
4. Remove dust seal (6), plug (7), and plugs (8) (4 pieces)
from swivel shaft (5).
5. Remove ring (10), O-ring (11), and packings (13) (8
pieces) from rotor (9).

50-110 PC45MR-5, PC55MR-5

50 DISASSEMBLY AND ASSEM- DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEM-
BLY BLY

METHOD FOR ASSEMBLING CENTER SWIVEL JOINT ASSEMBLY

Center swivel joint assembly
1. Install O-ring (11) and packings (13) (8 pieces) to rotor (9).
2. Install dust seal (6) to swivel shaft (5).
2 Dust seal lip:
Grease (G2-LI)
3. Install plug (7) (1 piece) and plugs (8) (4 pieces) to swivel
shaft (5).
REMARK
• Thoroughly degrease, clean and dry the threaded
parts.
• After installing, check that the plug end surface is lower
than the shaft end surface.
3 Plug (5):
16.8 to 22.6 Nm {1.71 to 2.3 kgm}
3 Plug (6):
16.7 to 24.5 Nm {1.7 to 2.5 kgm}
4. Set swivel shaft (5) on the block, install rotor (9) by tapping
it lightly with a plastic hammer, etc. by using a push tool.
REMARK
Take extreme care not to damage the slipper seal and O-
ring.
2 Contact surfaces of rotor and swivel shaft:
Grease (G2-LI)
5. Install ring (10), snap ring (4) and O-ring (3).
6. Install plate (2) with bolt (1).
3 Bolt (1):
39.2 to 49 Nm {4 to 5 kgm}

PC45MR-5, PC55MR-5 50-111

50 DISASSEMBLY AND ASSEM-
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY BLY

REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY

METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY

3. Remove drain plug (3), and drain the hydraulic oil.

6 Hydraulic tank:
20 ℓ
REMARK
Check that the hydraulic oil is completely drained, and
tighten drain plug (3).

Fuel tank
4. Remove the fuel tank assembly. For details, see “REMOVE AND INSTALL FUEL TANK ASSEMBLY”.
Cover
5. Remove bolts (4) (3 pieces), and remove cover (5).

50-112 PC45MR-5, PC55MR-5

50 DISASSEMBLY AND ASSEM-
BLY REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY

6. Remove clamps (6) (2 places).

7. Disconnect hose (7), and remove sub-tank (8).

8. Remove clamp (9).

9. Loosen clamp (10), and disconnect hose (11).

10. Remove bolts (12) (3 pieces), and remove chamber (13).

11. Remove bolts (14) (2 pieces), and remove cover (15).

12. Remove clamp (16), and disconnect hose (17).

PC45MR-5, PC55MR-5 50-113

50 DISASSEMBLY AND ASSEM-
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY BLY

13. Remove bolts (18) (3 pieces), and remove bracket (19).

Hydraulic tank assembly

14. Disconnect hoses (20) to (24).
(20): Swivel joint (T)
(21): Main valve (Ts)
(22): Main valve (Ptr)
(23): Solenoid valve (T)
(24): Floor (T) block
15. Disconnect hose (25).

16. Remove clamp (26), and disconnect suction hose (27).

17. Remove bolt (28).

18. Remove bolts (29) (4 pieces), sling hydraulic tank assem-
bly (30), and remove it.

4 Hydraulic tank assembly (30):

40 kg

50-114 PC45MR-5, PC55MR-5

50 DISASSEMBLY AND ASSEM-
BLY REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY

METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY

Hydraulic tank assembly
1. Sling hydraulic tank assembly (30), and set it on the ma-
chine.

4 Hydraulic tank assembly (30):

40 kg
2. Install hydraulic tank assembly (30) with bolts (29) (4
pieces).
2 Threaded portion of bolt (29):
Adhesive (LT-2)
3 Bolt (29):
98 to 123 Nm {10 to 12.5 kgm}
3. Install bolt (28).

4. Connect suction hose (27) with clamp (26).

3 Clamp (26):
8.8±0.5 Nm {0.9±0.05 kgm}

5. Connect hose (25).

6. Connect hoses (20) to (24).
(20): Swivel joint (T)
(21): Main valve (Ts)
(22): Main valve (Ptr)
(23): Solenoid valve (T)
(24): Floor (T) block

PC45MR-5, PC55MR-5 50-115

50 DISASSEMBLY AND ASSEM-
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY BLY

Cover
7. Install bracket (19) with bolts (18) (3 pieces).

8. Connect hose (17).

9. Install clamp (16).

10. Install cover (15) with bolts (14) (2 pieces).

11. Install chamber (13) with bolts (12) (3 pieces).

12. Connect hose (11), and fasten clamp (10).

13. Install clamp (9).

50-116 PC45MR-5, PC55MR-5

50 DISASSEMBLY AND ASSEM-
BLY REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY

14. Install sub-tank (8).

15. Connect hose (7).
16. Install clamps (6) (2 places).

17. Install cover (5) with bolts (4) (3 pieces).

Fuel tank
18. Install the fuel tank assembly. For details, see “REMOVE AND INSTALL FUEL TANK ASSEMBLY”.
19. Tighten drain plug (3).
3 Drain plug (3):
58.8 to 78.4 Nm {6 to 8 kgm}

20. Install cover (2) with bolts (1) (6 pieces).

Refilling hydraulic tank with oil

21. Check that the drain plug is closed before refilling.
22. Refill the hydraulic tank with Komatsu genuine oil to the specified level through the oil filler port. Start the
engine to circulate the oil through the piping, and check the oil level again.

5 Hydraulic tank:
20 ℓ
Air bleeding
23. Bleed air. For details, see TESTING AND ADJUSTING, “Bleed air from each part”.

PC45MR-5, PC55MR-5 50-117

50 DISASSEMBLY AND ASSEM-
REMOVE AND INSTALL MAIN PUMP ASSEMBLY BLY

REMOVE AND INSTALL MAIN PUMP ASSEMBLY

Tools for removal and installation of main pump assembly

New/Redesign
Necessity

Sketch
Q'ty
Symbol Part No. Part name Remarks

Removal and installation of main pump

A 796T-13S-1010 Torque adapter ● 1 ○
assembly

METHOD FOR REMOVING MAIN PUMP ASSEMBLY

3. Remove drain plug (3), and drain the hydraulic oil.

6 Hydraulic tank:
20 ℓ
REMARK
Check that hydraulic oil is completely drained, and then
tighten drain plug (3).

Floor
4. Open the floor. For details, see TESTING AND ADJUSTING, “METHOD FOR OPENING AND CLOSING
FLOOR”.

50-118 PC45MR-5, PC55MR-5

50 DISASSEMBLY AND ASSEM-
BLY REMOVE AND INSTALL MAIN PUMP ASSEMBLY

5. Remove bolts (4) and (5) (4 pieces) and bolts (5a) (2

pieces), and remove cover (6).

6. Remove bolts (7) (2 pieces), and remove heat insulation

plate (8).

7. Remove nuts (14) (4 places), and remove U-bolt.

8. Remove clamp (15), and remove exhaust pipe (16).

9. Disconnect hoses (19), (20) and (21). (Except for the ma-
chines ready for installation of quick coupler)

10. Disconnect the hoses (20), (21), and (30). (For the ma-
chines ready for installation of quick coupler)

PC45MR-5, PC55MR-5 50-119

50 DISASSEMBLY AND ASSEM-
REMOVE AND INSTALL MAIN PUMP ASSEMBLY BLY

11. Disconnect hoses (22) and (23).

12. Disconnect hoses (24) and (25).

13. Remove bolts (26) (4 pieces), and disconnect suction hose

(27).

14. Sling main pump assembly (29), and hold it.

15. Remove bolts (28) (4 pieces) by using torque adapter (A),
sling main pump assembly (29), and remove it.

4 Main pump assembly (29):

30 kg

METHOD FOR INSTALLING MAIN PUMP ASSEMBLY

1. Sling main pump assembly (13), and set it on the engine.

4 Main pump assembly (29):

30 kg

50-120 PC45MR-5, PC55MR-5

50 DISASSEMBLY AND ASSEM-
BLY REMOVE AND INSTALL MAIN PUMP ASSEMBLY

2. Install main pump assembly (29) with bolts (28) (4 pieces)

by using torque adapter (A).

3. Connect suction hose (27) with bolts (26) (4 pieces).

4. Connect hoses (24) and (25).

5. Connect hoses (22) and (23).

6. Connect hoses (19), (20) and (21). (Except for the ma-
chines ready for installation of quick coupler)

PC45MR-5, PC55MR-5 50-121

50 DISASSEMBLY AND ASSEM-
REMOVE AND INSTALL MAIN PUMP ASSEMBLY BLY

7. Connect the hoses (20), (21), and (30). (For the machines
ready for installation of quick coupler)

8. Install exhaust pipe (16) with clamp (15).

9. Fix exhaust pipe (16) with nuts (14) (4 places) and U-bolt.

10. Install heat insulation plate (8) with bolts (7) (2 pieces).

11. Install cover (6) with bolts (4) and (5) (4 pieces) and bolts
(5a) (2 pieces).

12. Tighten drain plug (3).

3 Drain plug (3):
58.8 to 78.4 Nm {6 to 8 kgm}

50-122 PC45MR-5, PC55MR-5

50 DISASSEMBLY AND ASSEM-
BLY REMOVE AND INSTALL MAIN PUMP ASSEMBLY

13. Install cover (2) with bolts (1) (6 pieces).

Floor
14. Close the floor. For details, see TESTING AND ADJUSTING, “METHOD FOR OPENING AND CLOSING
FLOOR”.
Refilling hydraulic tank with oil
15. Refill the hydraulic tank with Komatsu genuine oil to the specified level through the oil filler port. Start the
engine to circulate the oil through the piping, and check the oil level again.

5 Hydraulic tank:
20 ℓ
16. Bleed air from the hydraulic circuit. For details, see TESTING AND ADJUSTING, “Bleed air from each part”.

PC45MR-5, PC55MR-5 50-123

50 DISASSEMBLY AND ASSEM-
REMOVE AND INSTALL ACCUMULATOR ASSEMBLY BLY

REMOVE AND INSTALL ACCUMULATOR ASSEMBLY

METHOD FOR REMOVING ACCUMULATOR ASSEMBLY (EU SPECIFICATION)

Accumulator assembly
1. Release the remaining pressure from the hydraulic tank. See TESTING AND ADJUSTING, “METHOD FOR
RELEASING REMAINING PRESSURE FROM HYDRAULIC TANK”.
2. Remove the bolts (1) (3 pieces), and remove the cover (2).

3. Remove the bolt (3), and remove the cover (4).

4. Remove the bolts (5) (2 pieces), and remove the plate (6).

50-124 PC45MR-5, PC55MR-5

50 DISASSEMBLY AND ASSEM-
BLY REMOVE AND INSTALL ACCUMULATOR ASSEMBLY

5. Remove the bolts (7) (2 pieces), and remove the clamp

(8).
6. Move the hose aside so that it does not hinder the work.

7. Remove the nuts (9) (2 pieces), and remove U-bolt (10).

8. Remove the accumulator (11).

METHOD FOR REMOVING ACCUMULATOR ASSEMBLY (NORTH AMERICA

SPECIFICATION, FOR MACHINE WITH QUICK COUPLER)
Accumulator assembly
1. Release the remaining pressure from the hydraulic tank. See TESTING AND ADJUSTING, “METHOD FOR
RELEASING REMAINING PRESSURE FROM HYDRAULIC TANK”.
2. Remove the bolts (1) (3 pieces), and remove the cover (2).

PC45MR-5, PC55MR-5 50-125

50 DISASSEMBLY AND ASSEM-
REMOVE AND INSTALL ACCUMULATOR ASSEMBLY BLY

3. Remove the bolt (3), and remove the cover (4).

4. Remove the bolt (5), and remove the horn (6).

5. Remove the solenoid valve assembly bracket (7).

6. Remove the solenoid valve assembly (8).

7. Remove the accumulator (9).

50-126 PC45MR-5, PC55MR-5

50 DISASSEMBLY AND ASSEM-
BLY REMOVE AND INSTALL ACCUMULATOR ASSEMBLY

METHOD FOR INSTALLING ACCUMULATOR ASSEMBLY (EU SPECIFICATION)

Accumulator assembly
1. Install the accumulator (11).

2. Install U-bolt (10) with the nuts (9) (2 pieces).

3. Install the clamp (8) with the bolt (5).

4. Install the plate (6) with the bolts (5) (2 pieces).

5. Install the cover (4) with the bolt (3).

PC45MR-5, PC55MR-5 50-127

50 DISASSEMBLY AND ASSEM-
REMOVE AND INSTALL ACCUMULATOR ASSEMBLY BLY

6. Install the cover (2) with the bolts (1) (3 pieces).

METHOD FOR INSTALLING ACCUMULATOR ASSEMBLY (NORTH AMERICA

SPECIFICATION, FOR MACHINE WITH QUICK COUPLER)
Accumulator assembly
1. Install the accumulator (9) to the solenoid valve assembly.

2. Install the solenoid valve assembly bracket (7) to the re-

volving frame.

3. Install the solenoid valve assembly (8) to the solenoid

valve assembly bracket (7).

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50 DISASSEMBLY AND ASSEM-
BLY REMOVE AND INSTALL ACCUMULATOR ASSEMBLY

4. Install the horn (6) with the bolt (5).

5. Install the cover (4) with the bolt (3).

6. Install the cover (2) with the bolts (1) (3 pieces).

PC45MR-5, PC55MR-5 50-129

DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE 50 DISASSEMBLY AND ASSEM-
ASSEMBLY BLY

DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEM-

BLY
METHOD FOR DISASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY

Only precautions for disassembling the work equipment PPC valve assembly are explained below.
2 each of 2 different types of springs with different load at installed height are installed to springs (6) and (7).
Check the installing position (hydraulic port) to prevent any wrong installation.

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50 DISASSEMBLY AND ASSEM- DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE
BLY ASSEMBLY

METHOD FOR ASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY

Only precautions for disassembling and assembling the work equipment PPC valve assembly are explained be-
low.
NOTICE
Carefully clean and inspect the parts to prevent failure due to dust, rust, scratch, etc., and then take ex-
treme care when assembling them.
• Plugs (2) and (3) are not supplied.
• When assembling piston (8), apply grease (G2-LI) to the periphery of the piston and inside wall of the hole
of valve body (1).
• When installing spring (5), install the end surface of the smaller end turn diameter to shim (4) side.
End turn diameter of spring
• Smaller diameter end: φ4.9
• Larger diameter end: φ5.55
• As springs (6) and (7), different springs are used for different hydraulic ports. Check them before installing.
• Installed height: 34 mm (all)
• Load at installed height:
Spring (6) (P1, P2) 1.8 kg
Spring (7) (P3, P4) 1.0 kg
3 Bolt (11):
11.8 to 14.7 Nm {1.2 to 1.5 kgm}

PC45MR-5, PC55MR-5 50-131

DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE 50 DISASSEMBLY AND ASSEM-
ASSEMBLY BLY

• When installing joint (12) to body (1), apply Loctite accord-

ing to the following procedure.
1. When installing the joint, apply 1 drop (approximately
0.02 g) of Loctite (No. 648) to the female threaded
parts (A) (2 places) of the body. Before installing, thor-
oughly degrease and dry the threaded part of the joint
and the female threaded part of the body by using
parts cleaner.
2. The drop positions of Loctite are shown in the figure.
2 Female threaded part (A) of body:
Loctite (No. 648)
3 Joint (12):
39 to 49 Nm {4 to 5 kgm}
• Apply grease (G2-LI) to the contact surfaces of disc (13) and piston (8).
Application amount:
2 Rocking portion of joint:
Grease (G2-LI) (7 to 10 ml/entire circumference)
2 Rocking portion of disc and piston:
Grease (G2-LI) (0.3 to 0.8 ml/place)
• When assembling disc (13), adjust play of the lever end so that the play is within the range from 0.5 to
3 mm at the point of 200 mm from the rotation center.
See TESTING AND ADJUSTING, “ADJUST WORK EQUIPMENT AND SWING PPC VALVES”.
3 Nut (14):
69 to 88 Nm {7 to 9 kgm}

50-132 PC45MR-5, PC55MR-5

50 DISASSEMBLY AND ASSEM-
BLY DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY

DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY

METHOD FOR DISASSEMBLING TRAVEL PPC VALVE ASSEMBLY

1. Remove screw (22), and remove damper assembly (21).

2. Remove mounting bolt (14), and remove case (10), shaft (12), and lever (11) together as a unit.
3. Remove mounting bolts (16), and remove plate (13).
REMARK
• Check the thickness and installing position of washer (17).
• Pull out pin (23) from body (1).
4. Remove seal (8) and collar (9).
5. Pull out piston (7), and remove retainer (5), springs (6) and (4), and shim (3).
REMARK
Check the thickness and quantity of shim (3) at each installing position, and store them.
6. Pull out valve (2) from body (1).

PC45MR-5, PC55MR-5 50-133

50 DISASSEMBLY AND ASSEM-
DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY BLY

METHOD FOR ASSEMBLING TRAVEL PPC VALVE ASSEMBLY

k Carefully clean and inspect the parts to prevent failure due to dust, rust, scratch, etc., and then take
extreme care when assembling them.
1. When assembling piston (7), apply grease (G2-L1) to the periphery of the piston and inside wall of the hole
of valve body (1).
2. Install valve (2) to body (1).
3. When installing spring (4), install the end surface of the smaller end turn diameter to shim (3) side.
• End turn diameter of spring (inside diameter)
Small diameter: 4.9 mm
Large diameter: 5.16 mm
4. Apply grease (G2-LI) to the contact surfaces of lever (11) and piston (7) and to the contact surfaces of
damper (21) and pin (23).
2 Connecting portion of lever and piston:
Grease (G2-LI) (0.3 to 0.8 ml/place)
2 Connecting portion of damper and pin:
Grease (G2-LI) (0.3 to 0.8 ml/place)
5. Install retainer (5) and spring (6), and then install piston (7).
REMARK
Check the thickness and quantity of shim (3) at each installing position.
6. Install seal (8) and collar (9).
7. Install plate (13) with mounting bolts (16).
REMARK
Install washer (17) (t = 1.6). If the difference between the right and left full stroke angles exceeds 0.7 °, re-
duce it to 0.7 ° or less by changing the washer thickness. (When the washer thickness is decreased
0.3 mm, the full stroke angle increases 0.39 °.)

50-134 PC45MR-5, PC55MR-5

50 DISASSEMBLY AND ASSEM-
BLY DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY

Washer type and thickness = 1.0, 1.3, 1.6, 1.9, 2.2 mm

3 Bolt (16):
27 to 34 Nm {2.8 to 3.5 kgm}
8. Install shaft (12) and lever (11) to case (10), and install them with mounting bolt (14).
3 Bolt (14):
25 to 31 Nm {2.5 to 3.2 kgm}
9. Install damper assembly (21) with screw (22).

PC45MR-5, PC55MR-5 50-135

50 DISASSEMBLY AND ASSEM-
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY BLY

WORK EQUIPMENT
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY
k Place the machine on a level ground, and lower the work equipment to the ground in a stable pos-
ture.
k Set the lock lever to LOCK position.
k Disconnect (-) terminal of the battery after 2 minutes or more of engine stop or after checking that
the system operation lamp goes off.

METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY

Clamp, cover
1. Remove clamps (1), disconnect connector W2 (2), and re-
move it from the boom.

2. Remove mounting bolts (3) (2 pieces), and remove cover

(4).
REMARK
Keep the cylinder guide without losing it.

Hose
3. Disconnect hoses (5) to (12) (8 pieces). (Except for the
machines ready for installation of quick coupler)

4. Disconnect the hoses (20), (21), (22), (23), (24), (25), (26),
(27), (28), and (29) (10 pieces in total). (For the machines
ready for installation of quick coupler)

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50 DISASSEMBLY AND ASSEM-
BLY REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY

Work equipment assembly

5. Sling boom cylinder (13), and hold it.

4 Boom cylinder (13):

45 kg
6. Remove plate (14), and remove head side pin (15).
REMARK
Lower the boom cylinder onto block, etc.
7. Sling work equipment assembly (19), and hold it.

8. Remove plate (17), and remove boom foot pin (18).

9. Sling work equipment assembly (19), and remove it from

the machine body.

4 Work equipment assembly (19):

510 kg

METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY

Work equipment assembly
1. Sling work equipment assembly (19), and install it.

4 Work equipment assembly (19):

510 kg

PC45MR-5, PC55MR-5 50-137

50 DISASSEMBLY AND ASSEM-
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY BLY

2. Insert boom foot pin (18), and install plate (17).

k Never insert your finger into the pin hole when
aligning pin hole position.
2 Sliding surface on the pin and swing bracket side:
Molybdenum disulfide lubricant (LM-P)
2 Greasing after installation:
Grease (Hyper white grease)

3. Sling boom cylinder (13), and hold it.

4 Boom cylinder (13):

45 kg
4. Insert head side pin (15), and install plate (14).
k Never insert your finger into the pin hole when
aligning pin hole position.
2 Sliding surface on the pin and boom side:
Molybdenum disulfide lubricant (LM-P)
2 Greasing after installation:
Grease (Hyper white grease)
5. Adjust clearance (a) between boom cylinder head (14) and
boom (15) to 1 mm or lower by using shims.
Shim thickness: 1 mm

6. Connect hoses (5) to (12) (8 pieces). (Except for the ma-

chines ready for installation of quick coupler)

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50 DISASSEMBLY AND ASSEM-
BLY REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY

7. Connect the hoses (20), (21), (22), (23), (24), (25), (26),
(27), (28), and (29) (10 pieces in total). (For the machines
ready for installation of quick coupler)

8. Install cover (4) with mounting bolts (3) (2 pieces).

9. Install clamps (1) to the boom, and connect connector W2

(2).

Refilling hydraulic tank with oil

PC45MR-5, PC55MR-5 50-139

DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER AS- 50 DISASSEMBLY AND ASSEM-
SEMBLY BLY

DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEM-

BLY

Piston Disassembly Disassembly

Piston rod assembly, of cylinder
assembly cylinder head of piston head Piston rod A
assembly assembly assembly

A Cylinder

Tools for disassembly and assembly of work equipment cylinder assembly

New/Redesign
Necessity

Sketch
Q'ty
Symbol Part No. Part name Remarks

790-502-1003 Cylinder repair stand ■ 1 Disassembly and assembly of work

A
790-101-1102 Hydraulic pump ■ 1 equipment cylinder assembly

Removal and installation of cylinder

50-140 PC45MR-5, PC55MR-5

50 DISASSEMBLY AND ASSEM- DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER AS-
BLY SEMBLY

New/Redesign
Necessity

Sketch
Q'ty
Symbol Part No. Part name Remarks

790-201-1500 Push tool kit ■ 1

METHOD FOR DISASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY

Piston rod assembly
1. Set cylinder assembly (1) on cylinder repair stand (A).
2. Remove cylinder head assembly (2) by using wrench as-
sembly (B).

3. Sling piston rod assembly (4), and pull it out from tube (3).

PC45MR-5, PC55MR-5 50-141

DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER AS- 50 DISASSEMBLY AND ASSEM-
SEMBLY BLY

Piston assembly, cylinder head assembly

4. Set piston rod assembly (4) on cylinder repair stand (A).
5. Remove nut (5) by using socket (C).
Width across flats of nut (mm)
Boom Arm Bucket Swing Blade
PC45MR-5 65 60 50 55 55
PC55MR-5 65 65 50 55 55

6. Remove piston assembly (6) from piston rod (7).

7. Remove cushion plunger (8) from piston rod (7).

(Only for boom cylinder)

8. Remove cylinder head assembly (2) from piston rod (7).

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50 DISASSEMBLY AND ASSEM- DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER AS-
BLY SEMBLY

Disassembly of piston assembly

9. Remove wear ring (10) from piston (9).
10. Remove piston ring (11) from piston (9).

Disassembly of cylinder head assembly

11. Remove snap ring (12), and remove dust seal (13).
12. Remove rod packing (14).
13. Remove bushing (15).
14. Remove O-ring (16) and backup ring (17).

15. Remove O-ring (18) and backup rings (19) (2 pieces).

(Only for boom cylinder)

Piston rod
16. Remove dust seals (20) (2 pieces) from piston rod (7).
17. Remove bushing (21) from piston rod (7).

PC45MR-5, PC55MR-5 50-143

DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER AS- 50 DISASSEMBLY AND ASSEM-
SEMBLY BLY

Cylinder
18. Remove dust seals (22) (2 pieces) from cylinder (3).
19. Remove bushing (23) from cylinder (3).

METHOD FOR ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY

NOTICE
• Apply engine oil to the sliding surface of each part, and take care not to damage the packing, dust
seals, O-rings, etc.
• When inserting the backup ring, do not fit in it forcibly. Warm it in hot water at approximately 50 to
60 °C, and then insert it.
Cylinder
1. Press fit bushing (23) to cylinder (3).
2. Install dust seals (22) (2 pieces) to cylinder (3).

Piston rod
3. Press fit bushing (21) to piston rod (7).
4. Install dust seals (20) (2 pieces) of piston rod (7).

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50 DISASSEMBLY AND ASSEM- DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER AS-
BLY SEMBLY

Assembly of cylinder head assembly

5. Press fit bushing (15) by using push tool kit (D).
6. Install rod packing (14).
7. Press fit dust seal (13) by using push tool kit (E).
8. Install snap ring (12).
9. Install the backup ring (17) and O-ring (16).

10. Remove backup rings (19) (2 pieces) and O-ring (18).

(Only for boom cylinder)

Assembly of piston assembly

11. Set piston ring (11) on expander (F), and rotate the handle
by 8 to 10 turns to expand it.
12. Remove piston ring (11) from expander (F), and install it to
piston (9).

PC45MR-5, PC55MR-5 50-145

DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER AS- 50 DISASSEMBLY AND ASSEM-
SEMBLY BLY

13. Compress piston ring (11) by using ring (G).

14. Install wear ring (10) to piston (9).

Piston assembly, cylinder head assembly

15. Install cylinder head assembly (2) to piston rod (7).

16. Install cushion plunger (8) to piston rod (7).

(Only for boom cylinder)

17. Install piston assembly (6) to piston rod (7).

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50 DISASSEMBLY AND ASSEM- DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER AS-
BLY SEMBLY

18. Set piston rod assembly (4) on cylinder repair stand (A).
19. Install nut (5) by using socket (C).
Width across flats of nut (mm)
Boom Arm Bucket Swing Blade
PC45MR-5 65 60 50 55 55
PC55MR-5 65 65 50 55 55

2 Nut (5):
Loctite No. 262
REMARK
Tighten the nut with its machined surface facing the piston
side.
3 Nut (5) (boom) (PC45/55MR-5):
2.65±0.27 kNm {270±27 kgm}
3 Nut (5) (arm) (PC45MR-5):
2.16±0.22 kNm {220±22 kgm}
3 Nut (5) (arm) (PC55MR-5):
2.3±0.23 kNm {235±23.5 kgm}
3 Nut (5) (bucket) (PC45/55MR-5):
1.08±0.11 kNm {110±11.0 kgm}
3 Nut (5) (swing) (PC45/55MR-5):
1.42±0.14 kNm {145±14.5 kgm}
3 Nut (5) (blade) (PC45/55MR-5):
1.42±0.14 kNm {145±14.5 kgm}
Piston rod assembly
20. Set tube (3) on cylinder repair stand (A).
21. Sling piston rod assembly (4), and insert it into tube (3).
REMARK
Fully push the piston rod in.

22. Set cylinder assembly (1) on cylinder repair stand (A).

23. Install cylinder head assembly (2) by using wrench assem-
bly (B).
3 Cylinder head assembly (2) (boom)
(PC45/55MR-5):
736±73.6 Nm {75±7.5 kgm}
3 Cylinder head assembly (2) (arm) (PC45MR-5):
785±78.5 Nm {80±8.0 kgm}
3 Cylinder head assembly (2) (arm) (PC55MR-5):
961±96.1 Nm {98±9.8 kgm}
3 Cylinder head assembly (2) (bucket) (PC45MR-5):
785±78.5 Nm {80±8.0 kgm}

PC45MR-5, PC55MR-5 50-147

DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER AS- 50 DISASSEMBLY AND ASSEM-
SEMBLY BLY

3 Cylinder head assembly (2) (bucket) (PC55MR-5):

863±86.5 Nm {88±8.8 kgm}
3 Cylinder head assembly (2) (swing) (PC45MR-5):
676±67.6 Nm {69±6.9 kgm}
3 Cylinder head assembly (2) (swing) (PC55MR-5):
735±73.5 Nm {75±7.5 kgm}
3 Cylinder head assembly (2) (blade) (PC45/55MR-5):
931±93.1 Nm {95±9.5 kgm}

50-148 PC45MR-5, PC55MR-5

50 DISASSEMBLY AND ASSEM-
BLY REMOVE AND INSTALL OPERATOR'S CAB ASSEMBLY (CAB SPEC)

CAB AND ITS ATTACHMENTS

REMOVE AND INSTALL OPERATOR'S CAB ASSEMBLY (CAB SPEC)

Collecting
refrigerant
Draining Hydraulic tank Cab tilt Cover A

Hose, Operator’s cab

A connector assembly

k Place the machine on a level ground, and lower the work equipment to the ground in a stable pos-
ture.
k Set the lock lever to LOCK position.
k Disconnect (-) terminal of the battery after 2 minutes or more of engine stop or after checking that
the system operation lamp goes off.
k If you drain the radiator coolant when it is still hot, you may be scalded. Accordingly, wait for the
coolant temperature to drop before draining.
k If refrigerant gas (R134a) gets in your eyes, you may lose your sight. If it touches your skin, you may
suffer from frostbite. Accordingly, put on the protective eyeglasses, gloves and working clothes with
long sleeves while you are collecting or filling the refrigerant.
NOTICE
• Never release the refrigerant to the atmosphere.
• Ask a qualified person for collecting, adding and filling operations of the refrigerant (air conditioner
gas: R134a).
• Check the connector numbers and installed positions before disconnecting wiring and hoses, and
write them down.
• When disconnecting the wiring and hoses, take extreme care not to damage or deform the wiring
and hoses.

METHOD FOR REMOVING OPERATOR'S CAB ASSEMBLY (CAB SPEC)

Collecting refrigerant
1. Collect the refrigerant (air conditioner gas: R134a) from the air conditioner circuit (machine with air condi-
tioner).
Quantity of refrigerant to be collected: 550±50 g
Draining
2. Loosen drain valve (1), and drain the coolant.

6 Radiator:
8.9 ℓ
REMARK
Check that the coolant is completely drained, and tighten
drain plug (1).

PC45MR-5, PC55MR-5 50-149

50 DISASSEMBLY AND ASSEM-
REMOVE AND INSTALL OPERATOR'S CAB ASSEMBLY (CAB SPEC) BLY

Hydraulic tank
3. Release the remaining pressure in the hydraulic tank. For details, see TESTING AND ADJUSTING,
“METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC TANK”.
Cab tilt
4. Open the floor. For details, see TESTING AND ADJUSTING, “METHOD FOR OPENING AND CLOSING
FLOOR”.
Cover
5. Open cover (1a), and lock it.

6. Remove mounting bolts (4) (2 pieces), and remove cover

(5).

7. Disconnect heater hoses (6) and air conditioner tubes (7).

8. Remove mounting bolts (8a), and remove cover (8).

50-150 PC45MR-5, PC55MR-5

50 DISASSEMBLY AND ASSEM-
BLY REMOVE AND INSTALL OPERATOR'S CAB ASSEMBLY (CAB SPEC)

9. Remove rubber cover (9).

Hose, connector
10. Disconnect work equipment PPC hoses (10) to (17) (8
pieces)
Band color of hose (10): Brown
Band color of hose (11): Green
Band color of hose (12): Blue
Band color of hose (13): Yellow
Band color of hose (14): Red
Band color of hose (15): Brown
Band color of hose (16): Black
Band color of hose (17): White
11. Disconnect travel PPC hoses (18) to (21).
Band color of hose (18): Yellow, brown
Band color of hose (19): Yellow, orange
Band color of hose (20): Yellow, green
Band color of hose (21): Yellow, black
12. Disconnect swing PPC hoses (22) and (23).
Band color of hose (22): Red, white
Band color of hose (23): Blue, white

13. Disconnect connectors (24) to (27) at the front of the re-

volving frame, and ground cable (28).
Connector (24): F03
Connector (25): F04
Connector (26): F05
Connector (27): F06
Ground cable (28): T01

Operator's cab assembly

14. Sling the operator's cab assembly, and hold it.

PC45MR-5, PC55MR-5 50-151

50 DISASSEMBLY AND ASSEM-
REMOVE AND INSTALL OPERATOR'S CAB ASSEMBLY (CAB SPEC) BLY

15. Disconnect wire (29).

16. Loosen mounting bolts (30) (2 pieces) gradually and alter-
nately, and separate damper (31).

17. Disconnect hose (32).

18. Remove pin (33).
19. Remove right and left bolts (34), and pull out pin (35).

20. Sling operator's cab assembly (36), and remove it.

REMARK
• Check that all the wirings and pipings are disconnected
before removing.
• Pay attention to the balance when removing the as-
sembly.

4 Operator's cab assembly (36):

450 kg

METHOD FOR INSTALLING OPERATOR'S CAB ASSEMBLY (CAB SPEC)

Operator's cab assembly
1. Sling operator's cab assembly (36), and install it.
REMARK

4 Operator's cab assembly (36):

450 kg

2. Install pin (35), and install right and left bolts (34).
k Never insert your finger during position alignment.
3. Install pin (33).
4. Connect hose (32).

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50 DISASSEMBLY AND ASSEM-
BLY REMOVE AND INSTALL OPERATOR'S CAB ASSEMBLY (CAB SPEC)

5. Tighten bolts (30) (2 pieces) gradually and alternately to in-

stall damper (31).
6. Connect wire (29).

Hose, connector
7. Connect connectors (24) to (27) at the front of the revolv-
ing frame, and ground cable (28).
Connector (24): F03
Connector (25): F04
Connector (26): F05
Connector (27): F06
Ground cable (28): T01

8. Connect swing PPC hoses (22) and (23).

Band color of hose (22): Red, white
Band color of hose (23): Blue, white
9. Connect travel PPC hoses (18) to (21).
Band color of hose (18): Yellow, brown
Band color of hose (19): Yellow, orange
Band color of hose (20): Yellow, green
Band color of hose (21): Yellow, black
REMARK
Check the identification mark and color before connecting.
10. Connect work equipment PPC hoses (10) to (17) (8
pieces).
Band color of hose (10): Brown
Band color of hose (11): Green
Band color of hose (12): Blue
Band color of hose (13): Yellow
Band color of hose (14): Red
Band color of hose (15): Brown
Band color of hose (16): Black
Band color of hose (17): White
REMARK
Check the identification mark and color before connecting.

PC45MR-5, PC55MR-5 50-153

50 DISASSEMBLY AND ASSEM-
REMOVE AND INSTALL OPERATOR'S CAB ASSEMBLY (CAB SPEC) BLY

11. Install rubber cover (9).

Cover
12. Install cover (8) with mounting bolts (8a).

13. Connect heater hoses (6) and air conditioner tubes (7).

14. Install cover (5) with mounting bolts (4) (2 pieces).

15. Close cover (1a), and lock it.

16. Close the floor. For details, see TESTING AND ADJUST-
ING, “METHOD FOR OPENING AND CLOSING FLOOR”.

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50 DISASSEMBLY AND ASSEM-
BLY REMOVE AND INSTALL OPERATOR'S CAB ASSEMBLY (CAB SPEC)

Refilling radiator with coolant

17. Refill the radiator with coolant to the specified level through the coolant filler port. Run the engine to circu-
late the coolant, and then check the coolant level again.

5 Radiator:
8.9 ℓ
Refilling with oil (hydraulic tank)
18. Refill the hydraulic tank with Komatsu genuine oil to the specified level through the oil filler port. Start the
engine to circulate the oil through the piping, and check the oil level again.
Filling of refrigerant (air conditioner gas: R134a)
19. Refill the air conditioner circuit with refrigerant (air conditioner gas: R134a) (machine with air conditioner).
Filling quantity: 550±50 g

PC45MR-5, PC55MR-5 50-155

REMOVE AND INSTALL FLOOR FRAME ASSEMBLY (CANOPY 50 DISASSEMBLY AND ASSEM-
SPEC) BLY

REMOVE AND INSTALL FLOOR FRAME ASSEMBLY (CANOPY SPEC)

METHOD FOR REMOVING FLOOR FRAME ASSEMBLY (CANOPY SPEC)

Floor mat
1. Release the remaining pressure in the hydraulic tank. For details, see TESTING AND ADJUSTING,
“METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC TANK”.
2. Remove floor mat (1).
3. Open the floor. For details, see TESTING AND ADJUST-
ING, “METHOD FOR OPENING AND CLOSING FLOOR”.

Canopy
4. Sling canopy (2), hold it, and remove right and left mount-
ing bolts (3) (8 pieces).
5. Sling canopy (2), and remove it.

50-156 PC45MR-5, PC55MR-5

50 DISASSEMBLY AND ASSEM- REMOVE AND INSTALL FLOOR FRAME ASSEMBLY (CANOPY
BLY SPEC)

6. Remove mounting bolts (3), and remove cover (4).

7. Remove rubber cover (5).

Hose, connector
8. Disconnect work equipment PPC hoses (6) to (13) (8
pieces)
Band color of hose (6): Brown
Band color of hose (7): Green
Band color of hose (8): Blue
Band color of hose (9): Yellow
Band color of hose (10): Red
Band color of hose (11): Brown
Band color of hose (12): Black
Band color of hose (13): White
9. Disconnect travel PPC hoses (14) to (17).
Band color of hose (14): Yellow, brown
Band color of hose (15): Yellow, orange
Band color of hose (16): Yellow, green
Band color of hose (17): Yellow, black
10. Disconnect swing PPC hoses (18) and (19).
Band color of hose (18): Red, white
Band color of hose (19): Blue, white

11. Disconnect the connector F51 (31) under the floor. (For the
machines ready for installation of quick coupler)

PC45MR-5, PC55MR-5 50-157

REMOVE AND INSTALL FLOOR FRAME ASSEMBLY (CANOPY 50 DISASSEMBLY AND ASSEM-
SPEC) BLY

12. Disconnect connectors (20) to (23) at the front of the re-

volving frame, and ground cable (24).
Connector (20): F03
Connector (21): F04
Connector (22): F05
Connector (23): F06
Ground cable (24): T01
13. Sling the floor frame assembly, and hold it.

14. Disconnect wire (25).

15. Loosen mounting bolts (26) (2 pieces) gradually and alter-
nately, and separate damper (27).

Floor frame assembly

16. Remove pin (28).
17. Remove right and left mounting bolts (29), and remove pin
(30).

18. Sling floor frame assembly (31), and remove it.

REMARK
• Check that all the wirings and pipings are disconnected
before removing.
• Pay attention to the balance when removing the as-
sembly.

4 Floor frame assembly:

200 kg

50-158 PC45MR-5, PC55MR-5

50 DISASSEMBLY AND ASSEM- REMOVE AND INSTALL FLOOR FRAME ASSEMBLY (CANOPY
BLY SPEC)

METHOD FOR INSTALLING FLOOR FRAME ASSEMBLY (CANOPY SPEC)

Floor frame assembly
1. Sling floor frame assembly (31), and install it.

4 Floor frame assembly (31):

200 kg
2. Sling floor frame assembly (31), and hold it.

3. Install pin (29), and install right and left mounting bolts
(30).
k Never insert your finger during position alignment.
4. Install pin (28).

5. Tighten mounting bolts (26) (2 pieces) gradually and alter-

nately, and install damper (27).
6. Connect wire (25).

Hose, connector
7. Connect the connector F51 (31) under the floor. (For the
machines ready for installation of quick coupler)

PC45MR-5, PC55MR-5 50-159

REMOVE AND INSTALL FLOOR FRAME ASSEMBLY (CANOPY 50 DISASSEMBLY AND ASSEM-
SPEC) BLY

8. Connect connectors (20) to (23) at the front of the revolv-

ing frame, and ground cable (24).
Connector (20): F03
Connector (21): F04
Connector (22): F05
Connector (22): F06
Ground cable (24): T01

9. Disconnect swing PPC hoses (18) and (19).

Band color of hose (18): Red, white
Band color of hose (19): Blue, white
10. Connect travel PPC hoses (14) to (17).
Band color of hose (14): Yellow, brown
Band color of hose (15): Yellow, orange
Band color of hose (16): Yellow, green
Band color of hose (17): Yellow, black

11. Connect work equipment PPC hoses (6) to (13) (8 pieces).

Band color of hose (6): Brown
Band color of hose (7): Green
Band color of hose (8): Blue
Band color of hose (9): Yellow
Band color of hose (10): Red
Band color of hose (11): Brown
Band color of hose (12): Black
Band color of hose (13): White
12. Install rubber cover (5).

13. Install cover (4) with mounting bolts (3).

50-160 PC45MR-5, PC55MR-5

50 DISASSEMBLY AND ASSEM- REMOVE AND INSTALL FLOOR FRAME ASSEMBLY (CANOPY
BLY SPEC)

14. Sling canopy (2), hold it, and install right and left mounting
bolts (3) (8 pieces).
15. Close the floor. For details, see TESTING AND ADJUST-
ING, “METHOD FOR OPENING AND CLOSING FLOOR”.

16. Install floor mat (1).

Refilling with oil (hydraulic tank)

17. Refill the hydraulic tank with Komatsu genuine oil to the specified level through the oil filler port. Start the
engine to circulate the oil through the piping, and check the oil level again.

PC45MR-5, PC55MR-5 50-161

REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED 50 DISASSEMBLY AND ASSEM-
GLASS) BLY

REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS)

Tools for removal and installation of operator's cab glass (adhered glass)

New/Redesign
Necessity

Sketch
Q'ty
Symbol Part No. Part name Remarks

A 793-498-1210 Lifter (suction cup) ■ 2

REMARK
• Among 5 surfaces including the operator's cab ceiling, adhered window glasses are (1) to (9) shown in the
figure (ceiling part (9) is a clear plate).
• Always remove the front window assembly when front window glass (8) is to be replaced. (If the front win-
dow glass is installed to the operator's cab, it cannot be replaced.)

50-162 PC45MR-5, PC55MR-5

50 DISASSEMBLY AND ASSEM- REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED
BLY GLASS)

(1): R.H. sash window assembly (6): Lower door window glass
(2); R.H. front lower triangle window glass (7): Front window glass
(3): Rear window glass (8): Clear plate
(4): L.H. rear window glass (9): Center trim seal
(5): Upper door window glass (10): Dam rubber

METHOD FOR REMOVING OPERATOR CAB GLASS (ADHERED GLASS)

Remove the window glass to be replaced according to the following procedure.
Window glass
1. Remove the adhesive between damaged window glass
(12) and operator' cab (sheet metal) (13) by using seal cut-
ter (B).

PC45MR-5, PC55MR-5 50-163

REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED 50 DISASSEMBLY AND ASSEM-
GLASS) BLY

• When seal cutter (B) is not provided

1) Make a hole in the adhesive and dam rubber by
using a drill, and pass extra fine wire (C) through
the hole.
2) Pinch the both ends of the extra fine wire passed
through the hole with pliers (D), etc. (or wind it
around to fix) and move it to the right and left al-
ternately to cut the dam rubber.
Since the wire may be broken by the frictional
heat, apply lubricant to it.
(The figure shows the operator's cab on a wheel
loader.)
• If the window glass is broken in small pieces, they
may be removed with cutter knife (E) and a flat-head
screwdriver.
While widening the cut with a flat-head screwdriver,
cut the adhesive and dam rubber with a cutter knife
(E).
(The figure shows the operator's cab on a wheel load-
er.)
2. Remove the window glass.

METHOD FOR INSTALLING OPERATOR CAB GLASS (ADHERED GLASS)

Removal of adhesive and dam rubber
1. Remove the remaining adhesive and dam rubber from the
sheet metal (adhesion surfaces) of the operator's cab by
using a knife and scraper (F).
NOTICE
Remove the adhesive and dam rubber left on the sheet
metal surface so that they do not become influential to
the bonding effect of new adhesive. Be careful not to
damage the coating surface by excessive scraping. (If
the painted surfaces are damaged, adhesion will be
lowered.)
(The figure shows the operator's cab on a wheel loader.)
Removal of oil, dust, dirt, etc. from adhesion surfaces
2. Remove oil, dust, and dirt from adhering surfaces on oper-
ator's cab (13) side and window glass (14) side by using
white gasoline.
NOTICE
• Clean them thoroughly since insufficient cleaning
induces adhesion failure.
• Clean all the black parts on the back of the window
glass.
• After cleaning, leave them for 5 minutes or more
for air drying.

50-164 PC45MR-5, PC55MR-5

50 DISASSEMBLY AND ASSEM- REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED
BLY GLASS)

Application of primer
3. Apply primer (15).
NOTICE
• Never apply the incorrect primer since the primer
significantly affects the adhesion strength. If the in-
correct primer is applied, completely wipe it off by
the cleaning solvent.
• Do not use the primer if it expires the date of 4
months from its production.
• Make sure to use the primer within 2 hours after
opening the cap.
• Even when it is plugged again immediately after
opening, be sure to use it within 24 hours after
opening. (The primer must be disposed 24 hours
after it has been opened.)
1) Stir both primers for paint surface and for glass thoroughly before use.
REMARK
If the primer has been refrigerated, leave it in a room temperature for a half day or more, and stir it. (If it
is opened soon after having been refrigerated, condensation formed. Allow enough time for the primer
to become the room temperature.)
2) When reusing a brush (16) for applying the primer, clean it with white gasoline before use.
REMARK
• Check again that the brush is free from stains or fouling after cleaning.
• 2 brushes must be prepared separately, one for the primer for paint surface and another for glass.
3) Apply primer for paint surface evenly to the mounting
part of the dam rubber (10) of operator's cab (13) and
the place outside which adhesive is applied to.
NOTICE
• Limit the application of the primer to 2 times.
(Application beyond 2 times causes degrada-
tion.)
• After applying the primer, leave it for at least 5
minutes (maximum 8 hours) for air drying.
2 Primer for paint surface:
SUNSTAR Paint Surface Primer 580 SUPER
REMARK
Area to be coated: Entire area of dimension (a).
Primer application dimension (a): 25 mm

PC45MR-5, PC55MR-5 50-165

REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED 50 DISASSEMBLY AND ASSEM-
GLASS) BLY

4) Apply the glass primer to the mounting surface of win-

dow glass (14).
2 Glass primer:
SUNSTAR Glass Primer 580 SUPER
NOTICE
• Limit the application of the primer to 2 times.
(Application beyond 2 times causes degrada-
tion.)
• Do not apply the primer to Approximately 5 mm
of the border area between the black and trans-
parent parts on the window glass.
• After applying the primer, leave it for at least 5
minutes (maximum 8 hours) for air drying.
REMARK
Area to be coated: Apply the primer to the entire area
of adhesion position (b) which is a periphery of whole
area of window glass (14) relative to dam rubber (10)
mounting position and operator's cab (13).

Dam rubber
4. Attach dam rubber (double-sided adhesive tape) (10)
along the inner edge of window glass mounting surface.
REMARK
• The dam rubber is used to prevent the adhesive from
flowing out to shape the appearance, align the adhe-
sion thickness to stabilize the strength, and maintain
the glass until the adhesive is hardened.
• The dam rubber has 2 types of sectional dimensions.
Use the dam rubber separately as described below.
Dam rubber section size
• For general use: Thickness 5 mm x Width 7 mm
• For front sash: Thickness 5 mm x Width 5 mm
• Do not remove the tape on glass-adhering side of the
dam rubber until the window glass is installed.
• When installing the dam rubber, do not touch the
cleaned surface.
• Take care that the dam rubber is not floated in each
sticking corner.
• When bonding the dam rubber around a window, be
careful not to overlap the starting point with ending
point, or be sure to provide the clearance of approxi-
mately 5 mm in the joining area.
• Install the dam rubber according to each mounting por-
tion by referring to the following figure.

50-166 PC45MR-5, PC55MR-5

50 DISASSEMBLY AND ASSEM- REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED
BLY GLASS)

• Slide sash
Install the dam rubber along the adhesive surface pe-
riphery of the sash frame.

• Sheet metal part

Install the dam rubber along the sheet metal edge.

• Pipe material part

Align the dam rubber with the position where the pipe
round corner R ends, and install it.

• Front sash (glass adhesion side)

Both sides of the frame

PC45MR-5, PC55MR-5 50-167

REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED 50 DISASSEMBLY AND ASSEM-
GLASS) BLY

Bottom of the frame

Dimension (c): 2.4 mm

• Door (glass adhesion side)

Install the dam rubber along the door outer edge.
d: Inner
e: Outer

Application of adhesive
5. Apply adhesive.
NOTICE
• Do not use the adhesive if it expires the date of 6 months from its production.
• Adhesives must be stored at 25 °C or lower in a dark and cool place.
• Do not heat the adhesive 30 °C or higher.
• When reusing the adhesive, remove the hardened adhesive at the nozzle tip completely.
1) Break the aluminum dehumidification film (18) at the
mouth of adhesive cartridge (17), and attach the noz-
zle.

2) Cut the tip of adhesive nozzle (19) to dimensions (q)

and (r) shown in the figure.
Dimension (q): 10 mm
Dimension (r): 15 mm

50-168 PC45MR-5, PC55MR-5

50 DISASSEMBLY AND ASSEM- REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED
BLY GLASS)

3) Set adhesive cartridge (17) on caulking gun (G).

REMARK
A better workability is obtainable from a power caulk-
ing gun.
4) Remove the protective tape on the glass-bonding side
of dam rubber.

5) Apply adhesive (20) to the outside portion of dam rub-

ber (10) on the operator's cab.
2 Adhesive:
SUNSTAR Penguin Super 560
REMARK
• Apply adhesive (20) to dam rubber (10) of opera-
tor's cab (13) according to the dimensions (s) and
(t) indicated in the figure.
Dimension (s): 10 mm
Dimension (t): 15 mm
• Thickness of applied adhesive (20) must be higher
than that of dam rubber (10).
• Height of applied adhesive must be even.

Slide sash assembly

6. Install the slide sash assembly.
1) Clean the sash adhesion surface on the cab side and sash flange adhesion surface with cleaning sol-
vent according to step 1 and step 2 as previously described.
2) Apply the primer according to step 3 as previously described.
REMARK
Use the primer separately according to the sash type.

2 Primer:
• When the sash has metallic luster

SUNSTAR sash primer GP-402

2 Primer:
• When the sash is painted black (no metallic luster)

SUNSTAR Paint Surface Primer 435-95

REMARK
Do not apply the primer to the following water drain range.

PC45MR-5, PC55MR-5 50-169

REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED 50 DISASSEMBLY AND ASSEM-
GLASS) BLY

3) Install the dam rubber according to step 4 as previous-

ly described.
REMARK
When installing dam rubber (10) to the sash bottom,
avoid installing it to the range of dimension (v) in order
to drain water from the periphery of the sash.
Dimension (u): 150 mm
Dimension (v): 50 mm
4) Apply the adhesive according to step 5 as previously
described.
REMARK
Do not apply the adhesive to the above water drain
range.
5) Install slide sash assembly (1) to operator's cab main
unit (13).
REMARK
• Push the assembly securely so that there is no
clearance around it.
• If the adhesive protrudes, immediately wipe it off to
prevent the protruding adhesive from hardening.
6) After installing, fix the sash assembly with band, etc.
for approximately 10 hours.

Window glass
7. Install the window glass and clear plate.
1) Clean the glass adhesion surface on the cab side and adhesion surface on the glass side with cleaning
solvent according to step 2 as previously described.
2) Apply the primer according to step 3 as previously described.
3) Install the dam rubber according to step 4 as previously described.
4) Apply the adhesive according to step 5 as previously described.
5) Install the glass to the cab main unit.
NOTICE
• Since the window glass cannot be removed and installed again, install it with utmost cau-
tion.
• Window glass bonding work must be finished within 5 minutes from application of adhesive.

50-170 PC45MR-5, PC55MR-5

50 DISASSEMBLY AND ASSEM- REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED
BLY GLASS)

6) After bonding the window glass, press down entire cir-

cumference of the window glass until it firmly sticks to
dam rubber.
REMARK
• Especially, press the corners of the window glass
firmly.
• You can perform this work efficiently by pulling the
window glass from the inside of the operator's cab
by using lifter (A).
(The figure shows the operator's cab of PC200-7.)
REMARK
Fix mating faces of the rear glass corners with caulk-
ing material (21) while the clearance is secured as de-
scribed below.
Dimension (W): 3 mm
2 Caulking material:
GE TOSHIBA SILICONES TOSSEAL381
7) After adhesion, fix the sash assembly with band, etc.
for approximately 10 hours.
8. Cure the adhered window glass.
1) Keep the stopper rubbers, styrene foam blocks, and rubber bands installed for 10 hours of curing peri-
od.
(Ambient temperature 20 °C/ Humidity 60 %)
2) Before actual operation of the machine, leave it to
cure for 14 hours after the stopper rubbers, styrene
foam blocks, and rubber bands are removed, and for a
total of 24 hours after the adhesive is applied.
REMARK
• Attach the center trim seal to the lower part of front
window glass (8) after mounting it.
• When caulking, shape the adhesive on the left and
right end surfaces by using a rubber spatula, etc.
• Caulk the entire periphery so that there is no clear-
ance in area (x) between the glass and center trim
seal to eliminate any gap.
2 Adhesive:
Sika Japan Sikaflex 256HV

PC45MR-5, PC55MR-5 50-171

50 DISASSEMBLY AND ASSEM-
REMOVE AND INSTALL FRONT WINDOW ASSEMBLY BLY

REMOVE AND INSTALL FRONT WINDOW ASSEMBLY

METHOD FOR REMOVING FRONT WINDOW ASSEMBLY

Front window assembly
1. Lower the front window assembly.
2. Remove wiper motor (1) and wiper blade (2).
REMARK
Also remove wiper curl code from the sash, and fix it in the
operator's cab.

3. Remove rollers (3) (right and left) on the lower side of the
sash.

4. Remove bolts (4), and disconnect pull-up link (5) so that it

jumps up toward the ceiling.

50-172 PC45MR-5, PC55MR-5

50 DISASSEMBLY AND ASSEM-
BLY REMOVE AND INSTALL FRONT WINDOW ASSEMBLY

5. Hold the handles, remove the latches, and remove front

window assembly (6).

METHOD FOR INSTALLING FRONT WINDOW ASSEMBLY

Front window assembly
1. Install front window assembly (6), hold the handles to lock
the assembly with latches.

2. Install pull-up link (5) jumping up toward the ceiling and

sash with bolts (4).

3. Install rollers (3) (right and left) on the lower side of the
sash.

PC45MR-5, PC55MR-5 50-173

50 DISASSEMBLY AND ASSEM-
REMOVE AND INSTALL FRONT WINDOW ASSEMBLY BLY

4. Install wiper motor (1) and wiper blade (2).

REMARK
Install the wiper curl code.

50-174 PC45MR-5, PC55MR-5

50 DISASSEMBLY AND ASSEM-
BLY REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY

REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY

METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY

Collecting refrigerant
1. Collect the refrigerant (air conditioner gas: R134a) from the air conditioner circuit.
Quantity of refrigerant to be collected: 550±50 g
2. Drain the coolant.

6 Radiator:
8.9 ℓ
Front window
3. Hold handles (2) on both sides of the front window in the
operator's cab, and pull the window backward and unlock it
while lowering lock lever (3).

PC45MR-5, PC55MR-5 50-175

50 DISASSEMBLY AND ASSEM-
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY BLY

4. Pull up the front window, and securely push up handles (2)

until the lock engages at the position where the window
does not move backward, and store front window (upper
side) (1) in the ceiling.

Cover, connector
5. Remove floor mat (4).
6. Remove screws (5) (2 pieces), and remove cover (6).

7. Remove screws (7) (2 pieces), and remove cover (8).

8. Remove clamp (9), and disconnect connector F18 (10).

50-176 PC45MR-5, PC55MR-5

50 DISASSEMBLY AND ASSEM-
BLY REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY

9. Remove mounting bolt (11), and remove cover (12).

REMARK
Disconnect connector M01 (13) on the back side of cover
(12).

10. Remove mounting bolts (14) (4 pieces), and pull out ma-
chine monitor assembly (15) in the direction of the arrow.

11. Remove mounting bolt (16), and remove cover (17).

12. Remove mounting bolts (19) (4 pieces) of right lever stand

(18).
13. Move right lever stand (18) closer to the seat side.

PC45MR-5, PC55MR-5 50-177

50 DISASSEMBLY AND ASSEM-
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY BLY

14. Remove vents (20) (3 pieces).

15. Disconnect connectors (21) and (22).

16. Remove mounting bolts (23) (5 pieces), and remove cover
(24).

50-178 PC45MR-5, PC55MR-5

50 DISASSEMBLY AND ASSEM-
BLY REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY

Air conditioner unit assembly

17. Disconnect connectors (25) and (26).
18. Open the floor. For details, see TESTING AND ADJUST-
ING, “METHOD FOR OPENING AND CLOSING FLOOR”.

19. Remove mounting bolts (27) (2 pieces), and remove cover

(28).

20. Disconnect heater hoses (29) (2 pieces) and air condition-

er tubes (30) (2 pieces).
21. Remove mounting bolts (31) (4 pieces), and remove air
conditioner unit assembly (32).

METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY

Air conditioner unit assembly
1. Install air conditioner unit assembly (32) with mounting
bolts (31) (4 pieces).
2. Connect heater hoses (29) (2 pieces) and air conditioner
tubes (30) (2 pieces).

PC45MR-5, PC55MR-5 50-179

50 DISASSEMBLY AND ASSEM-
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY BLY

3. Install cover (28) with mounting bolts (27) (2 pieces).

4. Close the floor. For details, see TESTING AND ADJUST-
ING, “METHOD FOR OPENING AND CLOSING FLOOR”.

Cover, connector
5. Connect connectors (25) and (26).

6. Install cover (24) with mounting bolts (23) (5 pieces).

7. Connect connectors (21) and (22).

50-180 PC45MR-5, PC55MR-5

50 DISASSEMBLY AND ASSEM-
BLY REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY

8. Install vents (20) (3 pieces).

9. Install mounting bolts (19) (4 pieces) of right lever stand

(18).

10. Install cover (17) with mounting bolts (16) (2 pieces).

11. Insert machine monitor assembly (15) in the opposite di-

rection to the arrow, and install the assembly with mount-
ing bolts (14) (4 pieces).

PC45MR-5, PC55MR-5 50-181

50 DISASSEMBLY AND ASSEM-
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY BLY

12. Install cover (12) with mounting bolts (11) (6 pieces).

REMARK
Connect connector M01 (13) on the back side of cover
(12).

13. Connect connector F18 (10), and install clamp (9).

14. Install cover (8) with screws (7) (2 pieces).

15. Install cover (6) with screws (5) (2 pieces).

16. Install floor mat (4).

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50 DISASSEMBLY AND ASSEM-
BLY REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY

17. Pull down front window (upper side) (1) to the front.

18. Hold handles (2) on both sides of the front window in the
operator's cab, and push the window forward and lock it
while lowering lock lever (3).
19. Refill the radiator with coolant to the specified level
through the coolant filler port. Run the engine to circulate
the coolant, and then check the coolant level again.

5 Radiator:
8.9 ℓ
20. Refill the refrigerant (air conditioner gas: R134a) from the
air conditioner circuit.
Filling quantity: 550±50 g

PC45MR-5, PC55MR-5 50-183

50 DISASSEMBLY AND ASSEM-
REMOVE AND INSTALL OPERATOR'S SEAT BLY

REMOVE AND INSTALL OPERATOR'S SEAT

k Place the machine on a level ground and lower the work equipment to the ground in a stable pos-
ture.
k Operate the lock lever to LOCK position.
k Disconnect (-) terminal of the battery after 2 minutes or more of engine stop or after checking that
the system operation lamp goes off.
k Removal and installation work must be done by 2 persons.
REMARK
• Check the connector numbers and installed positions before disconnecting wiring and hoses, and write them
down.
• When disconnecting the wiring and hoses, take extreme care not to damage or deform the wiring and hoses.

METHOD FOR REMOVING OPERATOR'S SEAT

1. Pull lever (1) backward and move operator's seat (2) back-
ward.
2. Remove mounting bolts (3) (4 pieces).
REMARK
Move the operator's seat forward, and remove the mount-
ing bolts (2 pieces) at the rear.

3. Disconnect connector S19 (4) at the rear of the operator's

seat.
4. Remove operator's seat (2) while slowly lifting it by 2 per-
sons.

4 Operator's seat assembly:

25 kg

METHOD FOR INSTALLING OPERATOR'S SEAT

1. Install operator's seat (2) by 2 persons.

4 Operator's seat assembly:

25 kg
2. Connect connector S19 (4) at the rear of the operator's
seat.

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50 DISASSEMBLY AND ASSEM-
BLY REMOVE AND INSTALL OPERATOR'S SEAT

3. Install mounting bolts (3) (4 pieces).

REMARK
Move the operator's seat forward, and install mounting
bolts (2 pieces) at the rear.
4. Pull lever (1) backward and move operator's seat (2) to the
original position.

PC45MR-5, PC55MR-5 50-185

50 DISASSEMBLY AND ASSEM-
REMOVE AND INSTALL SEAT BELT BLY

REMOVE AND INSTALL SEAT BELT

METHOD FOR REMOVING SEAT BELT

Operator's seat
1. Remove the operator's seat. For details, see “REMOVE AND INSTALL OPERATOR'S SEAT”.
Seat belt
2. Remove mounting bolts (2) (1 piece each on right and left
sides) of seat belt (1), and remove seat belt (1).

METHOD FOR INSTALLING SEAT BELT

Seat belt
1. Install seat belt (1) with mounting bolts (2) (1 piece each
on the right and left).
3 Mounting bolt (2):
19.6 to 29.4 Nm {2.0 to 3.0 kgm}

Operator's seat
2. Install the operator's seat. For details, see “REMOVE AND INSTALL OPERATOR'S SEAT”.

50-186 PC45MR-5, PC55MR-5

50 DISASSEMBLY AND ASSEM-
BLY REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY

ELECTRICAL SYSTEM
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY
k Place the machine on a level ground, and lower the work equipment to the ground in a stable pos-
ture.
k Set the lock lever to LOCK position.
k Disconnect (-) terminal of the battery after 2 minutes or more of engine stop or after checking that
the system operation lamp goes off.

METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY

1. Open the floor. For details, see TESTING AND ADJUSTING, “METHOD FOR OPENING AND CLOSING
FLOOR”.
2. Disconnect ground cable (2).
REMARK
• Blow off and remove the dust around the engine before
starting the work.
• Be sure to disconnect ground cable (2) on the revolving
frame side.
3. Disconnect connector CE2 (3) and connector CE1 (4).
REMARK
• Before starting the work, blow air again to ensure that
there is no dust around the connector and (a) part to
prevent any failure from occurring and to make removal
and installation work easier.
• Put the masking on the connector part and engine con-
troller that have been removed.

4. Remove mounting bolts (4), and remove engine controller

assembly (5) together with bracket (6).
REMARK
Be careful that engine controller assembly (5) does not fall
off during removal.

5. Remove bolt (7), and remove ground (8).

6. Remove bolt (9), and remove engine controller assembly
(5).

PC45MR-5, PC55MR-5 50-187

50 DISASSEMBLY AND ASSEM-
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY BLY

METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY

1. Install engine controller assembly (5) with bolt (9).
2. Install ground (8) with bolt (7).

3. Install engine controller assembly (5) together with bracket

(6) with mounting bolts (4).
REMARK
Be careful that engine controller assembly (5) does not fall
when it is being installed.

4. Connect connector CE2 (3) and connector CE1 (4).

REMARK
Be careful not to allow dust to enter the clearance between
engine controller and connector CE2 (3), or between en-
gine controller and connector CE1 (4).
5. Connect ground cable (2).
REMARK
Be sure to connect ground cable (2) on the revolving frame
side.
6. Close the floor. For details, see TESTING AND ADJUSTING, “METHOD FOR OPENING AND CLOSING
FLOOR”.

50-188 PC45MR-5, PC55MR-5

50 DISASSEMBLY AND ASSEM-
BLY REMOVE AND INSTALL MACHINE CONTROLLER ASSEMBLY

REMOVE AND INSTALL MACHINE CONTROLLER ASSEMBLY

METHOD FOR REMOVING MACHINE CONTROLLER ASSEMBLY

KOMTRAX terminal assembly
1. Remove KOMTRAX terminal assembly. For details, see “REMOVE AND INSTALL KOMTRAX TERMINAL
ASSEMBLY”.
Cover
2. Remove mounting bolts (1) (4 pieces), and remove cover
(2).

Connector
3. Disconnect connector CP01 (3) and connector CP02 (4).
REMARK
• Before starting the work, blow air again to ensure that
there is no dust around the connector and (a) part to
prevent any failure from occurring and to make removal
and installation work easier.
• Pull up levers (5) of connector CP01 (3) and connector
CP02 (4) in the direction of the arrow while pressing
hook (b).
• Put the masking on the connector part and machine
controller assembly (7) that have been removed.

PC45MR-5, PC55MR-5 50-189

50 DISASSEMBLY AND ASSEM-
REMOVE AND INSTALL MACHINE CONTROLLER ASSEMBLY BLY

Machine controller assembly

4. Remove mounting bolts (6) (4 pieces), and remove ma-
chine controller assembly (7).

METHOD FOR INSTALLING MACHINE CONTROLLER ASSEMBLY

Machine controller assembly
1. Install machine controller assembly (7) with mounting bolts
(6) (4 pieces).
REMARK
Be careful that machine controller assembly (7) does not
fall when it is being installed.

Connector
2. Connect connector CP01 (3) and connector CP02 (4).
REMARK
• Be careful not to allow dust to enter the clearance be-
tween machine controller assembly (7) and connector
CP01 (3), or between the assembly and connector
CP02 (4).
• Pull down levers (5) of connector CP01 (3) and con-
nector CP02 (4) in the opposite direction to the arrow
while pressing hook (b).

50-190 PC45MR-5, PC55MR-5

50 DISASSEMBLY AND ASSEM-
BLY REMOVE AND INSTALL MACHINE CONTROLLER ASSEMBLY

Cover
3. Install cover (2) with mounting bolts (1) (4 pieces).

KOMTRAX terminal assembly

4. Install KOMTRAX terminal assembly. For details, see “REMOVE AND INSTALL KOMTRAX TERMINAL AS-
SEMBLY”.

PC45MR-5, PC55MR-5 50-191

50 DISASSEMBLY AND ASSEM-
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY BLY

REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY

METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY

Machine monitor assembly
1. Remove floor mat (1).
2. Remove screws (2) (2 pieces), and remove cover (3).

3. Remove screws (4) (2 pieces), and remove cover (5).

4. Remove clamp (6), and disconnect connector F18 (7).

50-192 PC45MR-5, PC55MR-5

50 DISASSEMBLY AND ASSEM-
BLY REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY

5. Remove mounting bolts (8) (4 pieces), and pull out ma-

chine monitor assembly (9) in the direction of the arrow.

6. Remove screws (10) (8 pieces), and remove covers (11)

and (11a).

7. Remove clamp (12), and disconnect connector F15 (13).

8. Remove mounting bolts (14) (4 pieces), and remove ma-
chine monitor assembly (9).

METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY

Machine monitor assembly
1. Install machine monitor assembly (9) with mounting bolts
(14) (4 pieces).
2. Connect connector F15 (13), and install clamp (12).

3. Install covers (11) and (11a) with screws (10) (8 pieces).

PC45MR-5, PC55MR-5 50-193

50 DISASSEMBLY AND ASSEM-
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY BLY

4. Insert machine monitor assembly (9) in the opposite direc-

tion to the arrow, and install the assembly with mounting
bolts (8) (4 pieces).

5. Connect connector F18 (7), and install clamp (6).

6. Install cover (5) with screws (4) (2 pieces).

7. Install cover (3) with screws (2) (2 pieces).

8. Install floor mat (1).

50-194 PC45MR-5, PC55MR-5

50 DISASSEMBLY AND ASSEM-
BLY REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY

REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY

k Place the machine on a level ground and lower the work equipment to the ground in a stable pos-
ture.
k Operate the lock lever to LOCK position.
k Disconnect (-) terminal of the battery after 2 minutes or more of engine stop or after checking that
the system operation lamp goes off.
REMARK
• Check the connector numbers and installed positions before disconnecting wiring and hoses, and write them
down.
• When disconnecting the wiring and hoses, take extreme care not to damage or deform the wiring and hoses.

METHOD FOR REMOVING KOMTRAX TERMINAL ASSEMBLY

Cover
1. Remove bolts (1), and remove cover (2).
(Canopy specification)

(Operator's cab specification)

REMARK
For the cab specification, disconnect connector (3) on the
back side of cover (1).

PC45MR-5, PC55MR-5 50-195

50 DISASSEMBLY AND ASSEM-
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY BLY

KOMTRAX terminal assembly

2. Remove connector CK1 (4) and connector CK2 (5).
3. Remove GPS antenna wiring (6).
4. Remove communication antenna wiring (7).
5. Remove mounting bolt (8), and remove KOMTRAX termi-
nal assembly (9).

METHOD FOR INSTALLING KOMTRAX TERMINAL ASSEMBLY

KOMTRAX terminal assembly
1. Install KOMTRAX terminal assembly (9) with mounting bolt
(8).
2. Install communication antenna wiring (7).
3. Install GPS antenna wiring (6).
4. Install connector CK1 (4) and connector CK2 (5).

Cover
5. Install cover (2), and install it with bolts (1).
(Canopy specification)

(Operator's cab specification)

50-196 PC45MR-5, PC55MR-5

50 DISASSEMBLY AND ASSEM-
BLY REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY

REMARK
For the cab specification, connect connector (3) on the
back side of cover (1).

PC45MR-5, PC55MR-5 50-197

60 MAINTENANCE STANDARD

S/T
Steering
STRG
SIG Signal
SOL Solenoid
STD Standard
OPT
Option
OP
PRESS Pressure
SPEC Specification
SW Switch
TEMP Temperature
T/C Torque Converter
T/M Transmission

60-8 PC45MR-5, PC55MR-5

60 MAINTENANCE STANDARD MAINTENANCE STANDARD FOR PTO

ENGINE AND COOLING SYSTEM

MAINTENANCE STANDARD FOR PTO

PC45MR-5, PC55MR-5 60-9

MAINTENANCE STANDARD OF COOLING SYSTEM 60 MAINTENANCE STANDARD

MAINTENANCE STANDARD OF COOLING SYSTEM

No. Item Judgment criteria Remedy

1 Tightening torque of clamp 5.9±0.49 Nm {0.6±0.05 kgm}
Retighten
2 Tightening torque of clamp 4.4±0.49 Nm {0.45±0.05 kgm}

60-10 PC45MR-5, PC55MR-5

60 MAINTENANCE STANDARD MAINTENANCE STANDARD OF SWING CIRCLE

POWER TRAIN
MAINTENANCE STANDARD OF SWING CIRCLE

Unit: mm
No. Item Judgment criteria Remedy
Standard clearance Allowable clearance
1 Clearance in bearing Replace
0.20 to 0.70 1.7

PC45MR-5, PC55MR-5 60-11

MAINTENANCE STANDARD OF SWING MACHINERY 60 MAINTENANCE STANDARD

MAINTENANCE STANDARD OF SWING MACHINERY

Unit: mm
No. Item Judgment criteria Remedy
Backlash between swing Standard clearance Allowable clearance
1 motor shaft and No. 1 sun
gear 0.04 to 0.11 -

Backlash between No. 1

2 sun gear and No. 1 plane- 0.12 to 0.28 0.6
tary gear
Backlash between No. 1
3 planetary gear and swing 0.14 to 0.38 0.6
machinery case
Backlash between No. 1
4 planetary carrier and No. 2 0.10 to 0.26 -
sun gear Replace
Backlash between No. 2
5 sun gear and No. 2 plane- 0.12 to 0.28 0.6
tary gear
Backlash between No. 2
6 planetary gear and swing 0.14 to 0.38 0.6
machinery case
Backlash between No. 2
7 planetary carrier and swing 0.016 to 0.097 -
pinion
Backlash between swing
8 0.14 to 0.73 2.0
pinion and swing circle

60-12 PC45MR-5, PC55MR-5

60 MAINTENANCE STANDARD MAINTENANCE STANDARD OF SWING MACHINERY

Unit: mm
No. Item Judgment criteria Remedy
Standard dimension Tolerance Repair limit
Repair hard
Wear of oil seal sliding sur-
9 0 chrome plating
face of swing pinion 55 54.8 or replace
-0.074

PC45MR-5, PC55MR-5 60-13

MAINTENANCE STANDARD OF SPROCKET 60 MAINTENANCE STANDARD

MAINTENANCE STANDARD OF SPROCKET

Unit: mm
No
Item Judgment criteria Remedy
.
Standard dimension Tolerance Repair limit
Wear of tooth bottom
1 +1.0
diameter 380.37 368
-2.0

Wear of tooth tip di- 0

2 423.99 412 Repair by
ameter -3.0 build-up
3 Wear of tooth tip width 26 - 24 welding or
replace
Wear of tooth bottom +0.5
4 33 30
width -1.0

Thickness of tooth +0.492

5 75.185 69
bottom -1.075

60-14 PC45MR-5, PC55MR-5

MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSH-
60 MAINTENANCE STANDARD ION

UNDERCARRIAGE AND FRAME

MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION

Unit: mm
No. Item Judgment criteria Remedy
Standard dimension Repair limit
Track Build-up weld-
120 124
1 Vertical width of frame ing for rebuild-
idler guard ing
Idler sup-
118 114
port
Track
Lateral width of 161 165 Repair by build-
frame
2 idler guide por- up welding or
tion Idler sup- replace
160 155
port
3 Tightening torque of bolt 98 to 123 Nm {10.0 to 12.5 kgm} Retighten
Instal- Load at in- Load at in-
Free height led stalled Free height stalled
height height height
4 Rubber 42.4 kN 39.0 kN Replace
302 202.2 294
shoe {4326 kg} {3980 kg}
Recoil spring
27.0 kN 24.0 kN
Steel shoe 302 238.2 294
{2748 kg} {2446 kg}
5 Tightening torque of bolt 157 to 196 Nm {16.0 to 20.0 kgm} Retighten

PC45MR-5, PC55MR-5 60-15

MAINTENANCE STANDARD OF IDLER 60 MAINTENANCE STANDARD

MAINTENANCE STANDARD OF IDLER

60-16 PC45MR-5, PC55MR-5

60 MAINTENANCE STANDARD MAINTENANCE STANDARD OF IDLER

Unit: mm
No. Item Judgment criteria Remedy

Outside diameter of protru- Standard dimension Repair limit

1
sion 377 -
2 Outside diameter of tread 335 327
Repair by
3 Depth of tread 21 25 build-up weld-
ing or replace
4 Thickness of tread 10.3 6.3
5 Width of tread 18 22
6 Overall width 75 -

Standard Tolerance Standard Allowable

dimension Shaft Hole clearance clearance
Clearance between shaft
7
and bushing -0.025 +0.142 0.105 to
35 -
-0.064 +0.080 0.206
Replace
Clearance between shaft -0.025 +0.060 0.025 to
8 35 -
and support -0.064 0 0.124

Standard clearance Allowable clearance

9 Axial play of idler
0.25 -

PC45MR-5, PC55MR-5 60-17

MAINTENANCE STANDARD OF TRACK ROLLER 60 MAINTENANCE STANDARD

MAINTENANCE STANDARD OF TRACK ROLLER

Unit: mm
No. Item Judgment criteria Remedy
Standard dimension Repair limit
1 Outside diameter of flange
123 -
2 Outside diameter of tread 95 87
Repair by
3 Thickness of tread 26.5 22.5 build-up weld-
ing or replace
4 Width of flange 41 35
5 Width of tread 34.5 -
6 Overall width 110 -

Standard Tolerance Standard Allowable

dimension Shaft Hole clearance clearance
Clearance between shaft
7
and bushing -0.025 +0.142 0.105 to
35 -
-0.050 +0.080 0.192
Replace
Clearance between shaft -0.025 +0.039 0.025 to
8 35 -
and collar -0.050 0 0.089

Standard clearance Allowable clearance

9 Axial play of roller
0.17 to 0.40 -

60-18 PC45MR-5, PC55MR-5

60 MAINTENANCE STANDARD MAINTENANCE STANDARD OF CARRIER ROLLER

MAINTENANCE STANDARD OF CARRIER ROLLER

Unit: mm
No. Item Judgment criteria Remedy
Standard dimension Repair limit
1 Outside diameter of tread
70 65 Repair by
build-up weld-
2 Thickness of tread 9 6.5 ing or replace
3 Width of tread 100 -

Standard Tolerance Standard Allowable

dimension Shaft Hole clearance clearance
Clearance between shaft
4
and support -0.050 +0.210 0.050 to
30 -
-0.100 0 0.310
Replace
Tolerance Standard Allowable
Standard
interfer- interfer-
dimension Shaft Hole
Interference between shaft ence ence
5
and seal
0 -0.200 0.148 to
30 -
-0.052 -0.400 0.400

PC45MR-5, PC55MR-5 60-19

MAINTENANCE STANDARD OF TRACK SHOE 60 MAINTENANCE STANDARD

MAINTENANCE STANDARD OF TRACK SHOE

(machine with steel shoe)

REMARK
*1: Triple grouser shoe
*2: Road liner

60-20 PC45MR-5, PC55MR-5

60 MAINTENANCE STANDARD MAINTENANCE STANDARD OF TRACK SHOE

Unit: mm
No
Item Judgment criteria Remedy
.
Standard dimension Turning limit Repair limit Usable up to turn-
1 Link pitch ing limit by turning
135 138 143
bushing and pin.
Outside diameter of Replace bushing
2 35 32 29
bushing and pin, or repair
link assembly after
3 Thickness of bushing 6.05 4.55 3.05 the repair limit has
been reached.
Standard dimension Repair limit
4 Height of link
65 59
Repair by build-up
Thickness of link welding or replace
5 (bushing press-fit 18.075 12.075
part)
Tolerance Allowa-
Standard
Standard di- ble in-
interfer-
mension Shaft Hole terfer-
Interference between ence
6 ence
bushing and link
Shaft: 35 +0.030 +0.040 0.110 to
-
Hole: 34.85 0 0 0.180

Interference between Shaft: 22.5 +0.060 +0.052 0.148 to

7 -
regular pin and link Hole: 22.3 0 0 0.260

Interference between Shaft: 22.5 -0.030 +0.052 0.078 to

8 - Replace
master pin and link Hole: 22.3 -0.070 0 0.170

Tolerance Allowa-
Standard
Standard di- ble
clear-
Clearance between mension Shaft Hole clear-
ance
9 regular pin and bush- ance
ing
Shaft: 22.5 +0.060 0.140 to
±0.2 -
Hole: 22.9 0 0.600

Clearance between Shaft: 22.5 -0.200 0.400 to

10 master pin and bush- ±0.2 -
Hole: 22.9 -0.400 1.000
ing
Standard clearance Standard clearance Allowable clear-
Clearance in link con- (one side) (both sides) ance (one side)
11
tact surface
0.7 to 1.4 1.4 to 2.8 -
Protrusion of regular Adjust
12 1.5
pin
Protrusion of master
13 3.25
pin
Tightening torque of
14 137±19.6 Nm {14±2 kgm} Retighten
shoe bolt

PC45MR-5, PC55MR-5 60-21

MAINTENANCE STANDARD OF TRIPLE SHOE 60 MAINTENANCE STANDARD

MAINTENANCE STANDARD OF TRIPLE SHOE

Unit: mm
No. Item Judgment criteria Remedy
Standard dimension Repair limit
1 Overall height of grouser
14 10
2 Overall height of shoe 20 16
3 Thickness of plate 6
Repair by
4 17 build-up weld-
Length of grouser base ing or replace
5 13
6 13
7 Length of grouser end 9
8 17

60-22 PC45MR-5, PC55MR-5

60 MAINTENANCE STANDARD MAINTENANCE STANDARD OF ROAD LINER

MAINTENANCE STANDARD OF ROAD LINER

Unit: mm
No. Item Judgment criteria Remedy
Standard dimension Repair limit
1 Height Replace
35 17

PC45MR-5, PC55MR-5 60-23

MAINTENANCE STANDARD FOR RUBBER SHOE 60 MAINTENANCE STANDARD

MAINTENANCE STANDARD FOR RUBBER SHOE

Unit: mm
No. Item Judgment criteria Remedy
Standard dimension Repair limit
1 Wear of lug height
25 5
2 Wear of roller guide 43 60
Replace
Wear of meshing portion of
3 2 -3
sprocket
Wear of contacting portion
4 25 19
of roller

60-24 PC45MR-5, PC55MR-5

60 MAINTENANCE STANDARD MAINTENANCE STANDARD OF HYDRAULIC TANK

HYDRAULIC SYSTEM
MAINTENANCE STANDARD OF HYDRAULIC TANK

No. Item Judgment criteria Remedy

1 Tightening torque of plug 58.8 to 78.5 Nm {6.0 to 8.0 kgm}
2 Tightening torque of nut 19.6 to 24.5 Nm {2.0 to 2.5 kgm}
Retighten
Tightening torque of el-
3 16.7 to 26.5 Nm {1.7 to 2.7 kgm}
bow

PC45MR-5, PC55MR-5 60-25

MAINTENANCE STANDARD OF MAIN PUMP 60 MAINTENANCE STANDARD

MAINTENANCE STANDARD OF MAIN PUMP

No. Item Judgment criteria Remedy

1 Tightening torque of bolt 11.8 to 14.7 Nm {1.2 to 1.5 kgm}
2 Tightening torque of bolt 5.9 to 9.8 Nm {0.6 to 1.0 kgm}
Tightening torque of
3 7.8 to 9.8 Nm {0.8 to 1.0 kgm} Retighten
breather
4 Tightening torque of bolt 27 to 34 Nm {2.8 to 3.5 kgm}
5 Tightening torque of plug 68.6 to 83.4 Nm {7.0 to 8.5 kgm}

60-26 PC45MR-5, PC55MR-5

60 MAINTENANCE STANDARD MAINTENANCE STANDARD OF MAIN PUMP

MAINTENANCE STANDARD OF MAIN PUMP SERVO VALVE

No. Item Judgment criteria Remedy

1 Tightening torque of plug 27.4 to 34.3 Nm {2.8 to 3.5 kgm}
Retighten
2 Tightening torque of bolt 9.8 to 12.7 Nm {1 to 1.3 kgm}

PC45MR-5, PC55MR-5 60-27

MAINTENANCE STANDARD OF PC-EPC VALVE 60 MAINTENANCE STANDARD

MAINTENANCE STANDARD OF PC-EPC VALVE

No. Item Criteria Remedy

1 Tightening torque of bolt 0.1 to 0.3 Nm {0.01 to 0.03 kgm}
Retighten
2 Tightening torque of bolt 9.8 to 12.7 Nm {1.0 to 1.3 kgm}

60-28 PC45MR-5, PC55MR-5

60 MAINTENANCE STANDARD MAINTENANCE STANDARD OF SWING MOTOR

MAINTENANCE STANDARD OF SWING MOTOR

PC45MR-5, PC55MR-5 60-29

MAINTENANCE STANDARD OF SWING MOTOR 60 MAINTENANCE STANDARD

Unit: mm
No. Item Judgment criteria Remedy
Standard dimension Repair limit
Replace (Re-
Free height Load at in- Load at in-
Installed Free place the spring
x outside di- stalled stalled
1 Check valve spring height height if damaged or
ameter height height
deformed as
3.33 N 2.66 N well)
13.0 x 6.5 7 -
{0.34 kg} {0.27 kg}

60-30 PC45MR-5, PC55MR-5

60 MAINTENANCE STANDARD MAINTENANCE STANDARD OF TRAVEL MOTOR

MAINTENANCE STANDARD OF TRAVEL MOTOR

PC45MR-5, PC55MR-5 60-31

MAINTENANCE STANDARD OF CONTROL VALVE 60 MAINTENANCE STANDARD

MAINTENANCE STANDARD OF CONTROL VALVE

9-spool valve

60-32 PC45MR-5, PC55MR-5

60 MAINTENANCE STANDARD MAINTENANCE STANDARD OF CONTROL VALVE

No. Item Judgment criteria Remedy

1 Tightening torque of bolt 7.85 to 9.8 Nm {0.8 to 1 kgm}
2 Tightening torque of bolt 29.4 to 34.3 Nm {3 to 3.5 kgm} Retighten
3 Tightening torque of bolt 9.8 to 12.7 Nm {1 to 1.3 kgm}

PC45MR-5, PC55MR-5 60-33

MAINTENANCE STANDARD OF CONTROL VALVE 60 MAINTENANCE STANDARD

60-34 PC45MR-5, PC55MR-5

60 MAINTENANCE STANDARD MAINTENANCE STANDARD OF CONTROL VALVE

Unit: mm
No. Item Judgment criteria Remedy
Tightening torque of suction
1 safety valve and suction 39.2 to 49 Nm {4 to 5 kgm}
valve plug Retighten
Tightening torque of main re-
2 49 to 58.8 Nm {5 to 6 kgm}
lief valve
Standard dimension Repair limit
Free height Load at in-
Installed Free Load at instal-
x outside di- stalled
3 Suction valve spring height height led height
ameter height
5.1 N 4.10 N Replace (Re-
39.2 x 4.45 33.5 - place spring if
{0.52 kg} {0.42 kg}
damaged or
22.6 N 18.1 N deformed as
4 Spool return spring 29 x 17.5 28.5 -
{2.3 kg} {1.84 kg} well)
30.2 N 24.2 N
5 Spool return spring 27.2 x 16.6 26.7 -
{3.08 kg} {2.46 kg}
21.6 N 17.3 N
6 Spool return spring 29 x 17.5 28.5 -
{2.2 kg} {1.76 kg}

PC45MR-5, PC55MR-5 60-35

MAINTENANCE STANDARD OF CONTROL VALVE 60 MAINTENANCE STANDARD

60-36 PC45MR-5, PC55MR-5

60 MAINTENANCE STANDARD MAINTENANCE STANDARD OF CONTROL VALVE

Unit: mm
No. Item Judgment criteria Remedy
1 Tightening torque of plug 117.6 to 161.8 Nm {12 to 16.5 kgm}
2 Tightening torque of plug 147 to 186.2 Nm {15 to 19 kgm}
3 Tightening torque of plug 147 to 186.2 Nm {15 to 19 kgm}
4 Tightening torque of plug 147 to 186.2 Nm {15 to 19 kgm} Retighten

Tightening torque of relief

5 39.2 to 49 Nm {4 to 5 kgm}
valve
6 Tightening torque of plug 19.6 to 27.5 Nm {2 to 2.8 kgm}
Standard dimension Repair limit
Free height Load at in-
Installed Free Load at in-
Back pressure check valve x outside di- stalled
7 height height stalled height
spring ameter height
10.9 N 8.73 N Replace (Re-
29.06 x 13.3 21 -
{1.11 kg} {0.89 kg} place spring if
44.3 N 35.5 N damaged or de-
8 Merge-divider valve spring 41.07 x 13.8 22 - formed as well)
{4.52 kg} {3.62 kg}
78.8 N 63.0 N
9 Cooler check valve spring 27.2 x 13.2 21 -
{8.04 kg} {6.43 kg}
Pressure compensation 7.45 N 5.96 N
10 15.4 x 6 8 -
valve spring {0.76 kg} {0.61 kg}

PC45MR-5, PC55MR-5 60-37

MAINTENANCE STANDARD OF CONTROL VALVE 60 MAINTENANCE STANDARD

60-38 PC45MR-5, PC55MR-5

60 MAINTENANCE STANDARD MAINTENANCE STANDARD OF CONTROL VALVE

Unit: mm
No. Item Judgment criteria Remedy
1 Tightening torque of plug 65.7 to 82.3 Nm {6.7 to 8.4 kgm}
Tightening torque of relief
2 49 to 58.8 Nm {5 to 6 kgm}
valve
3 Tightening torque of plug 19.6 to 24.5 Nm {2 to 2.5 kgm}
Tightening torque of unload Retighten
4 19.6 to 24.5 Nm {2 to 2.5 kgm}
valve
Tightening torque of relief
5 14.7 to 19.6 Nm {1.5 to 2.0 kgm}
valve
6 Tightening torque of plug 14.7 to 19.6 Nm {1.5 to 2.0 kgm}
Standard dimension Repair limit
Free height Load at in-
Installed Free Load at in-
x outside di- stalled
7 Check valve spring height height stalled height
ameter height
1.96 N 1.57 N Replace (Re-
28.5 x 5.4 25 -
{0.2 kg} {0.16 kg} place spring if
1.96 N 1.57 N damaged or de-
8 Check valve spring (boom) 16.4 x 7.5 9.8 - formed as well)
{0.2 kg} {0.16 kg}
1.96 N 1.57 N
9 Check valve spring (boom) 21.9 x 5 15.8 -
{0.2 kg} {0.16 kg}
5.49 N 4.41 N
10 Logic valve spring 10.98 x 6.2 9.5 -
{0.56 kg} {0.45 kg}

PC45MR-5, PC55MR-5 60-39

MAINTENANCE STANDARD OF CONTROL VALVE 60 MAINTENANCE STANDARD

60-40 PC45MR-5, PC55MR-5

60 MAINTENANCE STANDARD MAINTENANCE STANDARD OF CONTROL VALVE

Unit: mm
No. Item Judgment criteria Remedy
1 Tightening torque of plug 15.7 to 20.6 Nm {1.6 to 2.1 kgm}
2 Tightening torque of plug 24.5 to 34.3 Nm {2.5 to 3.5 kgm}
3 Tightening torque of plug 98 to 122.5 Nm {10 to 12.5 kgm}
Tightening torque of safety
4 137 to 157 Nm {14 to 16 kgm} Retighten
valve
5 Tightening torque of valve 24.5 to 34.3 Nm {2.5 to 3.5 kgm}
6 Tightening torque of plug 19.6 to 24.5 Nm {2 to 2.5 kgm}
7 Tightening torque of plug 117.6 to 161.8 Nm {12 to 16.5 kgm}
Standard dimension Repair limit
Replace (Re-
Free height Load at in-
Installed Free Load at instal- place spring if
x outside di- stalled
8 Check valve spring height height led height damaged or
ameter height
deformed as
1.96 N 1.57 N well)
21.9 x 5 15.8 -
{0.2 kg} {0.16 kg}

10-spool valve
REMARK
For the standard values other than section AC-AC of 10-spool valve, see the 9-spool valve.

PC45MR-5, PC55MR-5 60-41

MAINTENANCE STANDARD OF CONTROL VALVE 60 MAINTENANCE STANDARD

60-42 PC45MR-5, PC55MR-5

60 MAINTENANCE STANDARD MAINTENANCE STANDARD OF CONTROL VALVE

Unit: mm
No. Item Judgment criteria Remedy
Standard dimension Repair limit
Free height Load at in-
Installed Free Load at instal- Replace (Re-
x outside di- stalled
1 Spool return spring height height led height place spring if
ameter height
damaged or
22.6 N 18.1 N deformed as
29 x 17.5 28.5 -
{2.3 kg} {1.84 kg} well)
Pressure compensation 7.45 N 5.96 N
2 15.4 x 6 8 -
valve spring {0.76 kg} {0.61 kg}

PC45MR-5, PC55MR-5 60-43

MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING
PPC VALVE 60 MAINTENANCE STANDARD

MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC

VALVE

60-44 PC45MR-5, PC55MR-5

MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING
60 MAINTENANCE STANDARD PPC VALVE

PC45MR-5, PC55MR-5 60-45

MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING
PPC VALVE 60 MAINTENANCE STANDARD

Unit: mm
No. Item Judgment criteria Remedy
Standard dimension Repair limit
Free height Load at in- Load at in-
Installed
Centering spring (for ports x outside stalled Free height stalled
1 height
P3, P4) diameter height height Replace (Re-
place the
38.71 x 9.81 N 7.85 N
34 - spring if dam-
15.5 {1.00 kg} {0.80 kg}
aged or de-
Centering spring (for ports 42.48 x 17.7 N 14.1 N formed as well)
2 34 -
P1, P2) 15.5 {1.8 kg} {1.44 kg}
26.53 x 16.7 N 13.3 N
3 Metering spring 24.9 -
8.15 {1.70 kg} {1.36 kg}

60-46 PC45MR-5, PC55MR-5

60 MAINTENANCE STANDARD MAINTENANCE STANDARD OF BLADE PPC VALVE

MAINTENANCE STANDARD OF BLADE PPC VALVE

PC45MR-5, PC55MR-5 60-47

MAINTENANCE STANDARD OF BLADE PPC VALVE 60 MAINTENANCE STANDARD

Unit: mm
No. Item Judgment criteria Remedy
Standard dimensions Repair limit
Free height Load at in- Load at in-
Installed Replace (Re-
x outside stalled Free height stalled
1 Centering spring height place spring if
diameter height height
damaged or
33.88 x 125 N 100 N deformed as
28.4 -
15.3 {12.7 kg} {10.2 kg} well)
16.7 N 13.3 N
2 Metering spring 22.73 x 8.1 22 -
{1.7 kg} {1.36 kg}

60-48 PC45MR-5, PC55MR-5

60 MAINTENANCE STANDARD MAINTENANCE STANDARD OF BOOM SWING PPC VALVE

MAINTENANCE STANDARD OF BOOM SWING PPC VALVE

PC45MR-5, PC55MR-5 60-49

MAINTENANCE STANDARD OF BOOM SWING PPC VALVE 60 MAINTENANCE STANDARD

Unit: mm
No. Item Judgment criteria Remedy
Standard dimension Repair limit
Free height Load at in- Load at in-
Installed Replace (Re-
x Outside stalled Free height stalled
1 Centering spring height place the
diameter height height
spring if dam-
33.88 x 125 N 100 N aged or de-
28.4 -
15.3 {12.7 kg} {10.2 kg} formed as well)
16.7 N 13.3 N
2 Metering spring 22.73 x 8.1 22 -
{1.7 kg} {1.36 kg}

60-50 PC45MR-5, PC55MR-5

60 MAINTENANCE STANDARD MAINTENANCE STANDARD OF TRAVEL PPC VALVE

MAINTENANCE STANDARD OF TRAVEL PPC VALVE

PC45MR-5, PC55MR-5 60-51

MAINTENANCE STANDARD OF TRAVEL PPC VALVE 60 MAINTENANCE STANDARD

60-52 PC45MR-5, PC55MR-5

60 MAINTENANCE STANDARD MAINTENANCE STANDARD OF TRAVEL PPC VALVE

Unit: mm
No. Item Judgment criteria Remedy
Standard dimensions Repair limit
Free height Load at in- Load at in-
Installed
x outside stalled Free height stalled Replace the
1 Centering spring height
diameter height height spring if dam-
52.06 x 135 N 108 N aged or de-
31.9 -
15.5 {13.8 kg} {11.0 kg} formed
24.04 x 16.7 N 13.3 N
2 Metering spring 23.05 -
8.16 {1.7 kg} {1.36 kg}

PC45MR-5, PC55MR-5 60-53

MAINTENANCE STANDARD OF ATTACHMENT PPC VALVE 60 MAINTENANCE STANDARD

MAINTENANCE STANDARD OF ATTACHMENT PPC VALVE

60-54 PC45MR-5, PC55MR-5

60 MAINTENANCE STANDARD MAINTENANCE STANDARD OF ATTACHMENT PPC VALVE

PC45MR-5, PC55MR-5 60-55

MAINTENANCE STANDARD OF CENTER SWIVEL JOINT 60 MAINTENANCE STANDARD

MAINTENANCE STANDARD OF CENTER SWIVEL JOINT

Unit: mm
No. Item Judgment criteria Remedy
Standard dimen- Allowable clear-
Clearance between rotor and Standard clearance
1 sion ance Replace
shaft
60 0.055 to 0.085 0.090

60-56 PC45MR-5, PC55MR-5

60 MAINTENANCE STANDARD MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE

WORK EQUIPMENT
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE

PC45MR-5, PC55MR-5 60-57

MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE 60 MAINTENANCE STANDARD

60-58 PC45MR-5, PC55MR-5

60 MAINTENANCE STANDARD MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE

PC45MR-5, PC55MR-5
Unit: mm
Judgment criteria
No
Item Standard di- Tolerance Standard Allowable Remedy
.
mension Shaft Hole clearance clearance

Clearance Re-
between volving -0.036 +0.095 0.070 to
1 120
mounting frame -0.090 +0.034 0.185
pin and side
bushing of Replace pin and
1.0
revolving Boom bushing
frame and swing -0.036 +0.054 0.036 to
2 boom 120
brack- -0.090 0 0.144
swing et side
bracket
Clearance Boom
between swing -0.025 +0.039 0.025 to
3 50
mounting brack- -0.064 0 0.103
pin and et side
Replace pin and
bushing of 1.0
bushing
boom
swing Boom -0.025 +0.086 0.060 to
4 50
bracket side -0.064 +0.035 0.150
and boom
Inside diameter of
bushing insertion
portion on boom +0.030 Machining after
5 swing bracket side 60 - - -
0 build-up welding
in joint of boom
swing bracket and
boom
Clearance between
mounting pin and -0.025 +0.039 0.025 to Replace pin and
6 bushing of boom 50 1.0
-0.087 0 0.126 bushing
swing bracket and
boom cylinder
Inside diameter of
bushing insertion
portion on boom -0.030 Machining after
7 60 - - -
side in joint of boom -0.060 build-up welding
swing bracket and
boom
Clearance between
mounting pin and -0.025 +0.089 0.060 to Replace pin and
8 50 1.0
bushing of boom -0.064 +0.035 0.153 bushing
and arm
Inside diameter of
hole to insert bush- -0.079 Machining after
9 ing on arm side at 60 - - -
-0.119 build-up welding
joint of boom and
arm

PC45MR-5, PC55MR-5 60-59

MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE 60 MAINTENANCE STANDARD

Unit: mm
Judgment criteria
No
Item Standard di- Tolerance Standard Allowable Remedy
.
mension Shaft Hole clearance clearance

Clearance between
mounting pin and -0.170 -0.012 0.100 to Replace pin and
10 45 1.0
bushing of arm and -0.230 -0.060 0.218 bushing
bucket
Inside diameter of
hole to insert bush- -0.030 Machining after
11 ing on arm side at 55 - - -
-0.060 build-up welding
joint of arm and
bucket
Clearance between
mounting pin and -0.170 -0.012 0.105 to Replace pin and
12 45 1.0
bushing of arm and -0.230 -0.065 0.218 bushing
link
Inside diameter of
hole to insert bush- -0.030 Machining after
13 55 - - -
ing on arm side at -0.060 build-up welding
joint of arm and link
Clearance between
mounting pin and -0.170 -0.012 0.105 to Replace pin and
14 45 1.0
bushing of link and -0.230 -0.065 0.218 bushing
bucket
Clearance between -0.170 -0.012 0.105 to Replace pin and
15 mounting pin and 45 1.0
-0.230 -0.065 0.218 bushing
bushing of links
Clearance between
mounting pin and -0.025 +0.142 0.105 to Replace pin and
16 35 1.0
bushing of track -0.087 +0.080 0.229 bushing
frame and blade

60-60 PC45MR-5, PC55MR-5

60 MAINTENANCE STANDARD MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE

Unit: mm
Judgment criteria
Width of boss Width of hinge
No. Item Standard Remedy
Standard di- Standard di- clearance
Tolerance Tolerance
mension mension
0 +0.5
276 278.5 2.5 to 3.5
-0.5 0 Adjust the clear-
Joint of revolving
ance to Max.
17 frame and boom U17: Insert the shim of 0.8 mm thickness (1) 0.5 mm by using
swing bracket
L17: Insert the shims of 0.8 mm thickness (2) and 0.5 mm thickness shims.
(2)
-0.5 +0.5
250 250 0.5 to 1.5 Adjust the clear-
Joint of boom -1.0 0 ance to Max.
18 swing bracket and
L18: Insert the shim of 0.5 mm thickness (1) 0.5 mm by using
boom
shims.
R18: -
0 +1.5
60 60 0.5 to 2.0 Adjust the clear-
Joint of boom -0.5 +0.5 ance to Max.
19 swing cylinder
1.0 mm by using
and swing bracket L19: -
shims.
R19: Insert the shim of 1.0 mm thickness (1)
0 +2.0
60 64.5 4.5 to 7.0
-0.5 0 Adjust the clear-
Joint of revolving
ance to Max.
20 frame and boom L20: - 0.5 mm by using
swing cylinder
R20: Insert the shims of 1.0 mm thickness (4) and 0.5 mm thickness shims.
(1)
0 +1.5
60 60 0.5 to 2.0 Adjust the clear-
Joint of boom -0.5 +0.5 ance to Max.
21 swing bracket and
L21: Insert the shim of 1.0 mm thickness (1) 1.0 mm by using
boom cylinder
shims.
R21: -
0 +1.0
60 60.5 0.5 to 2.0 Adjust the clear-
Joint of boom and -0.5 0 ance to Max.
22
boom cylinder L22: - 0.5 mm by using
shims.
R22: Insert the shim of 1.0 mm thickness (1)
-0.3 +0.5
163 163 0.3 to 1.5 Adjust the clear-
Joint of boom and -1.0 0 ance to Max.
23
arm L23: - 0.5 mm by using
shims.
R23: Insert the shim of 0.5 mm thickness (1)
0 +1.0
55 55.5 0.5 to 2.0 Adjust the clear-
Joint of boom and -0.5 0 ance to Max.
24
arm cylinder L24: - 1.0 mm by using
shims.
R24: Insert the shim of 1.0 mm thickness (1)
0 +1.0
55 55.5 0.5 to 2.0 Adjust the clear-
Joint of arm cylin- -0.5 0 ance to Max.
25
der and arm L25: Insert the shim of 1.0 mm thickness (2) 1.0 mm by using
shims.
R25: -

PC45MR-5, PC55MR-5 60-61

MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE 60 MAINTENANCE STANDARD

Unit: mm
Judgment criteria
Width of boss Width of hinge
No. Item Standard Remedy
Standard di- Standard di- clearance
Tolerance Tolerance
mension mension
0 +1.0
55 55.5 0.5 to 2.0 Adjust the clear-
Joint of arm and -0.5 0 ance to Max.
26
bucket cylinder L26: Insert the shim of 1.0 mm thickness (2) 1.0 mm by using
shims.
R26: -
+0.7
168 170 ±1 0.3 to 2.8
Joint of arm and +0.2
27 -
bucket L27: -
R27: -
+0.7
168 170 ±1 0.3 to 2.8
Joint of link and +0.2
28 -
bucket L28: -
R28: -
- - - - - Adjust the clear-
ance to Max. 0.5
29 Joint of links L29: Insert the shim of 1.0 mm thickness (1) to 1.5 mm by us-
R29: - ing shims
+0.7
168 - - - Adjust the clear-
Joint of arm and +0.2 ance to Max. 0.5
30
link L30: Insert the shim of 1.0 mm thickness (1) to 1.5 mm by us-
ing shims
R30: -
+1.0
48 ±0.5 50 1.5 to 3.5 Adjust the clear-
Joint of track 0 ance to Max.
31
frame and blade L31: - 1.0 mm by using
shims.
R31: Insert the shim of 1.0 mm thickness (4)
0 +1.0
65 66 1.0 to 2.5 Adjust the clear-
Joint of track -0.5 0 ance to Max.
32 frame and blade
L32: Insert the shim of 1.0 mm thickness (4) 1.0 mm by using
cylinder
shims.
R32: -
0 +1.0
65 67 2.0 to 3.5 Adjust the clear-
Joint of blade and -0.5 0 ance to Max.
33
blade cylinder L33: - 1.0 mm by using
shims.
R33: Insert the shim of 1.0 mm thickness (3)

The number in ( ) after each shim thickness indicates the quantity of shim to be provided.

60-62 PC45MR-5, PC55MR-5

60 MAINTENANCE STANDARD MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE

DIMENSION OF ARM
PC45MR-5

Unit: mm
PC45MR-5
No. Tolerance
Measuring point Standard dimension
Shaft Hole
-0.025 +0.1
1 - 45
-0.064 0
+1
Arm side 55.5
0
2
0
Cylinder head side 55
-0.5

PC45MR-5, PC55MR-5 60-63

MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE 60 MAINTENANCE STANDARD

Unit: mm
PC45MR-5
No. Tolerance
Measuring point Standard dimension
Shaft Hole
-0.025 +0.039
3 - 50
-0.064 0
+0.5
Boom side 163
0
4
-0.3
Arm side 163
-1.0
5 - 100.2 ±1
6 - 216.7 ±1
7 - 312.1 ±1
8 - 1695 ±3
+1
9 - 1368.8
-3
10 - 193.3 ±1
11 - 12.6 ±1
12 - 330 ±0.5
13 - 303 ±0.5
14 - 230.3 ±0.5
15 - 870 -
-0.170 -0.050
16 - 45
-0.230 -0.089
+0.7
Link side 168
17 +0.2
Bucket side 170 ±1
-0.170 -0.050
18 - 45
-0.230 -0.089
+0.7
Arm side 168
19 +0.2
Bucket side 170 ±1
Minimum 900 ±1.5
20
Maximum 1480 -

60-64 PC45MR-5, PC55MR-5

60 MAINTENANCE STANDARD MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE

PC55MR-5

Unit: mm
PC55MR-5
No. Tolerance
Measuring point Standard dimension
Shaft Hole
-0.025 +0.1
1 - 45
-0.064 0
+1
Arm side 55.5
0
2
0
Cylinder head side 55
-0.5

PC45MR-5, PC55MR-5 60-65

MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE 60 MAINTENANCE STANDARD

Unit: mm
PC55MR-5
No. Tolerance
Measuring point Standard dimension
Shaft Hole
-0.025 +0.039
3 - 50
-0.064 0
+0.5
Boom side 163
0
4
-0.3
Arm side 163
-1.0
5 - 117 ±1
6 - 199.4 ±0.5
7 - 375.3 ±0.5
8 - 1640 ±3
9 - 1364.5 ±1
10 - 193.3 ±1
11 - 12.8 ±1
12 - 330 ±0.5
13 - 303 ±0.5
14 - 230.3 ±0.5
15 - 871 -
-0.170 -0.050
16 - 45
-0.230 -0.089
+0.7
Link side 168
17 +0.2
Bucket side 170 ±1
-0.170 -0.050
18 - 45
-0.230 -0.089
+0.7
Arm side 168
19 +0.2
Bucket side 170 ±1
Minimum 900 ±1.5
20
Maximum 1480 -

60-66 PC45MR-5, PC55MR-5

60 MAINTENANCE STANDARD MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE

DIMENSIONS OF BUCKET

Unit: mm
PC45MR-5, PC55MR-5
No.
Measuring point Standard dimension Tolerance
1 - 230.3 ±0.5
2 - 0 -
3 - 719.6 -
4 - 55 -
5 - 55 -
6 - 45 ° -
7 - 45 ° -
8 - 13.5 -
9 - 170 ±1
10 - 60 -
11 - 42 -
12 - 258 ±1
13 - 85 -
14 - 85 -
-0.050
15 - 45
-0.089

PC45MR-5, PC55MR-5 60-67

MAINTENANCE STANDARD OF BOOM CYLINDER 60 MAINTENANCE STANDARD

MAINTENANCE STANDARD OF BOOM CYLINDER

PC45MR-5, PC55MR-5

Unit: mm
No. Item Judgment criteria Remedy

Standard Tolerance Standard Allowable

dimension Shaft Hole clearance clearance
Clearance between piston Replace the
1
rod and bushing -0.030 +0.163 cylinder head
0.036 to
55 0.539
-0.076 -0.006 0.239

Clearance between piston -0.147 +0.142 0.227 to

2 rod support shaft and 50 1.0
-0.209 +0.080 0.351
bushing Replace pin
Clearance between cylin- and bushing
-0.025 +0.142 0.105 to
3 der bottom support shaft 50 1.0
-0.087 +0.080 0.229
and bushing
Tightening torque of cylin-
4 735±73.5 Nm {75±7.5 kgm}
der head
Retighten
Tightening torque of cylin-
5 2.65±0.27 kNm {270±27 kgm} (Width across flats: 65 mm)
der piston nut

60-68 PC45MR-5, PC55MR-5

60 MAINTENANCE STANDARD MAINTENANCE STANDARD OF ARM CYLINDER

MAINTENANCE STANDARD OF ARM CYLINDER

REMARK
The figure shows PC45MR-5.

PC45MR-5
Unit: mm
No. Item Judgment criteria Remedy

Standard di- Tolerance Standard Allowable

mension Shaft Hole clearance clearance
Clearance between piston Replace the
1
rod and bushing -0.025 +0.164 bushing
0.032 to
50 0.528
-0.064 +0.007 0.228

Clearance between piston -0.025 +0.142 0.105 to

2 rod support shaft and bush- 45 1.0
-0.064 +0.080 0.206
ing Replace pin
Clearance between cylinder and bushing
-0.025 +0.142 0.105 to
3 bottom support shaft and 45 1.0
-0.087 +0.080 0.229
bushing
Tightening torque of cylinder
4 785±78.5 Nm {80±8.0 kgm}
head
Retighten
Tightening torque of cylinder
5 2.16±0.22 kNm {220±22 kgm} (Width across flats: 60)
piston nut

PC55MR-5
Unit: mm
No. Item Judgment criteria Remedy

Standard di- Tolerance Standard Allowable

mension Shaft Hole clearance clearance
Clearance between piston Replace the
1
rod and bushing -0.030 +0.163 bushing
0.036 to
55 0.539
-0.076 +0.006 0.239

Clearance between piston -0.025 +0.142 0.105 to

2 rod support shaft and bush- 45 1.0
-0.064 +0.080 0.206
ing Replace pin
Clearance between cylinder and bushing
-0.025 +0.142 0.105 to
3 bottom support shaft and 45 1.0
-0.087 +0.080 0.229
bushing

PC45MR-5, PC55MR-5 60-69

MAINTENANCE STANDARD OF ARM CYLINDER 60 MAINTENANCE STANDARD

Unit: mm
No. Item Judgment criteria Remedy
Tightening torque of cylinder
4 961±96.1 Nm {98±9.8 kgm}
head
Retighten
Tightening torque of cylinder
5 2.30±0.23 kNm {235±23.5 kgm} (Width across flats: 65)
piston nut

60-70 PC45MR-5, PC55MR-5

60 MAINTENANCE STANDARD MAINTENANCE STANDARD OF BUCKET CYLINDER

MAINTENANCE STANDARD OF BUCKET CYLINDER

REMARK
The figure shows PC45MR-5.

PC45MR-5
Unit: mm
No. Item Judgment criteria Remedy

Standard di- Tolerance Standard Allowable

mension Shaft Hole clearance clearance
Clearance between piston Replace the
1
rod and bushing -0.025 +0.152 bushing
0.032 to
45 0.539
-0.087 +0.007 0.239

Clearance between piston -0.170 +0.142 0.250 to

2 rod support shaft and bush- 45 1.0
-0.230 +0.080 0.372
ing Replace pin
Clearance between cylinder and bushing
-0.025 +0.142 0.105 to
3 bottom support shaft and 45 1.0
-0.064 +0.080 0.206
bushing
Tightening torque of cylinder
4 785±78.5 Nm {80±8.0 kgm}
head
Retighten
Tightening torque of cylinder
5 1.08±0.11 kNm {110±11.0 kgm} (Width across flats: 50 mm)
piston nut

PC55MR-5
Unit: mm
No. Item Judgment criteria Remedy

Standard di- Tolerance Standard Allowable

mension Shaft Hole clearance clearance
Clearance between piston Replace the
1
rod and bushing -0.025 +0.164 bushing
0.032 to
50 0.528
-0.064 +0.007 0.228

Clearance between piston -0.170 +0.142 0.250 to

2 rod support shaft and bush- 45 1.0
-0.230 +0.080 0.372
ing Replace pin
Clearance between cylinder and bushing
-0.025 +0.142 0.105 to
3 bottom support shaft and 45 1.0
-0.064 +0.080 0.206
bushing

PC45MR-5, PC55MR-5 60-71

MAINTENANCE STANDARD OF BUCKET CYLINDER 60 MAINTENANCE STANDARD

Unit: mm
No. Item Judgment criteria Remedy
Tightening torque of cylinder
4 863±86.5 Nm {88±8.8 kgm}
head
Retighten
Tightening torque of cylinder
5 1.08±0.11 kNm {110±11.0 kgm} (Width across flats: 50 mm)
piston nut

60-72 PC45MR-5, PC55MR-5

60 MAINTENANCE STANDARD MAINTENANCE STANDARD OF BLADE CYLINDER

MAINTENANCE STANDARD OF BLADE CYLINDER

PC45MR-5,PC55MR-5

Unit: mm
No. Item Judgment criteria Remedy

Standard di- Tolerance Standard Allowable

mension Shaft Hole clearance clearance
Clearance between piston Replace the
1
rod and bushing -0.025 +0.164 bushing
0.032 to
50 0.528
-0.064 +0.007 0.228

Clearance between piston -0.030 +0.174 0.130 to

2 rod support shaft and bush- 55 1.0
-0.076 +0.100 0.250
ing Replace pin
Clearance between cylinder and bushing
-0.030 +0.174 0.130 to
3 bottom support shaft and 55 1.0
-0.076 +0.100 0.250
bushing
Tightening torque of cylinder
4 931±93.1 Nm {95±9.5 kgm}
head
Retighten
Tightening torque of cylinder
5 1.42±0.14 kNm {145±14.5 kgm} (Width across flats: 55 mm)
piston nut

PC45MR-5, PC55MR-5 60-73

MAINTENANCE STANDARD OF BOOM SWING CYLINDER 60 MAINTENANCE STANDARD

MAINTENANCE STANDARD OF BOOM SWING CYLINDER

REMARK
The figure shows PC45MR-5.

PC45MR-5
Unit: mm
No. Item Judgment criteria Remedy

Standard di- Tolerance Standard Allowable

mension Shaft Hole clearance clearance
Clearance between piston Replace the
1
rod and bushing -0.025 +0.164 bushing
0.032 to
50 0.551
-0.087 +0.007 0.251

Clearance between piston -0.025 +0.142 0.105 to

2 rod support shaft and bush- 50 1.0
-0.064 +0.080 0.206
ing Replace pin
Clearance between cylinder and bushing
-0.025 +0.142 0.105 to
3 bottom support shaft and 50 1.0
-0.064 +0.080 0.206
bushing
Tightening torque of cylinder
4 676.2±67.6 Nm {69±6.9 kgm}
head
Retighten
Tightening torque of cylinder
5 1.42±0.14 kNm {145±14.5 kgm} (Width across flats: 55)
piston nut

PC55MR-5
Unit: mm
No. Item Judgment criteria Remedy

Standard di- Tolerance Standard Allowable

mension Shaft Hole clearance clearance
Clearance between piston Replace the
1
rod and bushing -0.025 +0.164 bushing
0.032 to
50 0.551
-0.087 +0.007 0.251

Clearance between piston -0.025 +0.142 0.105 to

2 rod support shaft and bush- 50 1.0
-0.064 +0.080 0.206
ing Replace pin
Clearance between cylinder and bushing
-0.025 +0.142 0.105 to
3 bottom support shaft and 50 1.0
-0.064 +0.080 0.206
bushing

60-74 PC45MR-5, PC55MR-5

60 MAINTENANCE STANDARD MAINTENANCE STANDARD OF BOOM SWING CYLINDER

Unit: mm
No. Item Judgment criteria Remedy
Tightening torque of cylinder
4 735±73.5 Nm {75±7.5 kgm}
head
Retighten
Tightening torque of cylinder
5 1.42±0.14 kNm {145±14.5 kgm} (Width across flats: 55)
piston nut

PC45MR-5, PC55MR-5 60-75

80 APPENDIX

S/T
Steering
STRG
SIG Signal
SOL Solenoid
STD Standard
OPT
Option
OP
PRESS Pressure
SPEC Specification
SW Switch
TEMP Temperature
T/C Torque Converter
T/M Transmission

80-8 PC45MR-5, PC55MR-5

80 APPENDIX PRECAUTIONS FOR REFRIGERANT

AIR CONDITIONER SYSTEM

PRECAUTIONS FOR REFRIGERANT
k If refrigerant gas (air conditioner gas: R134a) gets in your eyes, you may lose your sight. And if it
touches your skin, you may suffer from frostbite. Put on protective eyeglasses, gloves and working
clothes with long sleeves while collecting the refrigerant or filling the air conditioner circuit with the
refrigerant.
k When replacing the air conditioner unit, air conditioner compressor, condenser or receiver drier, etc.,
collect the refrigerant (air conditioner gas: R134a) from the air conditioner circuit before disconnect-
ing the air conditioner hoses.
NOTICE
• Never release the refrigerant (air conditioner gas: R134a) to the atmosphere.
• Ask a qualified person for collecting, adding and filling operations of the refrigerant (air conditioner
gas: R134a).

PC45MR-5, PC55MR-5 80-9

AIR CONDITIONER COMPONENT 80 APPENDIX

AIR CONDITIONER COMPONENT

A: Vents C. Fresh air inlet

B: Recirculation air inlet
1: Air conditioner unit 6: Hot water piping
2: Hot water return piping 7: Air conditioner compressor
3: Refrigerant piping 8: FRESH/RECIRC air changeover lever
4: Receiver drier 9: Duct
5: Condenser 10: Air conditioner controlo panel Ass'y

80-10 PC45MR-5, PC55MR-5

80 APPENDIX SPECIFICATIONS OF AIR CONDITIONER

SPECIFICATIONS OF AIR CONDITIONER

Refrigerant: R134a
Quantity of refrigerant to be refilled: 650±50 g

PC45MR-5, PC55MR-5 80-11

CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE 80 APPENDIX

CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE

Cycle Compression Condensation Expansion Evaporation
(component) (compressor) (condenser) (Expansion valve) (Evaporator)
Location of Engine compartment Front part of radiator Inside of operator's cab Inside of operator's cab
component (built in air conditioner (built in air conditioner
unit) unit)
Function Circulates refrigerant Condenses refrigerant Decreases temperature Absorbs heat from air
and increases tem- to discharge heat ab- and pressure of refriger- around evaporator to
perature and pres- sorbed in evaporator. ant with throttle and con- cool that air by evapo-
sure of gas refriger- (condensation of re- vert it partially into gas so rating refrigerant.
ant so that it is lique- frigerant) that it is evaporated easi- (Evaporation of refriger-
fied easily in con- ly, and controls flow rate. ant)
denser. (Throttling of refrigerant)
(Compression of re-
frigerant)
State of refrig- Gas → gas Gas → liquid Liquid → liquid, gas Liquid, gas → gas
erant Adiabatic compres- Isobaric change Adiabatic expansion Isobaric change
sion

80-12 PC45MR-5, PC55MR-5

80 APPENDIX OUTLINE OF REFRIGERATION CYCLE

OUTLINE OF REFRIGERATION CYCLE

Regeneration cycles are composed of the following 4 processes. Refrigerant circulates around the system re-
peatedly changing its phase from liquid → gas → liquid.
Compression (Compressor)
• The compressor sucks in the refrigerant which is evaporated in the evaporator and compresses the refriger-
ant until it can be easily liquefied at the ambient temperature.
• The gas refrigerant sucked in the compressor cylinder is compressed to make the pressure higher. When
the refrigerant is cooled at the ambient temperature, it can be easily liquefied.
Condensation (Condenser)
• The condenser cools and liquefies the high-temperature and high-pressure gas refrigerant sent from the
compressor at the ambient temperature.
• The heat radiation from the condenser to the atmosphere is called the condensation heat.
• The amount of condensation heat is the sum total of the heat absorbed by the evaporator from the air in the
cab and the quantity of the work applied (the value converted into a heat quantity) by compression of the
compressor.
• The refrigerant liquefied in the condenser is dehydrated in the modulator and cooled further in the sub-cool
section to increase the cooling efficiency
• In the condensation process, gas refrigerant and liquid refrigerant are mixed.
• The temperature (condensation temperature) and the pressure (condensation pressure) at which the gas-
eous refrigerant is liquefied are proportional to each other.
Reference: The pressure varies depending on the condensation temperature of the refrigerant.
Expansion (Expansion valve)
• The expansion valve reduces the liquid refrigerant pressure to a level where liquid refrigerant can be easily
evaporated by the throttle action (*1).
• The action of reducing the pressure of the liquid refrigerant to a state where it easily evaporates before
sending it to the evaporator is called expansion.
• The expansion valve used for expansion reduces the refrigerant pressure and controls the refrigerant flow
simultaneously.
• The quantity of the liquid refrigerant that can be evaporated in the evaporator depends on the amount of
heat (refrigeration load) to be removed under the specific evaporation temperature (evaporation pressure).
• The expansion valve controls the refrigerant supply rate to prevent too much or too little supply of the liquid
refrigerant.
(*1) Throttle action
• If there is a narrow section in the passage through which liquid is flowing at a constant rate, a resistance to
the flow is generated.
When the liquid passes through a narrow section, cross-sectional area suddenly increases. The liquid ex-
pansion causes pressure and temperature to decrease.
• No heat is transferred between inside and outside by the throttle action.
Evaporation (Evaporator)
• The evaporator evaporates the liquid refrigerant (superheated vapor).
• The refrigerant evaporates, while absorbing an amount of heat necessary for evaporation (evaporation
heat) from the air around the cooling fins (air in the cab).
• The cooled air is sent into the cab by the blower fan, and it decreases the temperature in the cab.
• In the evaporator, the misty refrigerant sent from the expansion valve and the evaporated gas refrigerant
are mixed together.
• The temperature (evaporation temperature) and the pressure (evaporation pressure) at which the liquid re-
frigerant is evaporated are proportional to each other.

PC45MR-5, PC55MR-5 80-13

OUTLINE OF REFRIGERATION CYCLE 80 APPENDIX

• To evaporate the liquid refrigerant at lower temperature, the pressure in the evaporator must be kept as low
as possible. For this purpose, the compressor sucks in the evaporated refrigerant.
Relation between refrigerant and cooling trouble
• While repeating the refrigeration cycle, the refrigerant circulates in the refrigeration circuit and dissipates
the heat in the cab to the outside of the cab.
• If there is an insufficient quantity of refrigerant, all of it is evaporated while it is passing through the evapora-
tor. This causes evaporator efficiency to deteriorate, which will result in defective air conditioning.
• If there is excessive refrigerant, not all of it is evaporated and part of it will be sucked into the compressor in
liquid form, which causes the compressor to compress the liquid and may damage the components.
• If water is contained in the refrigerant circuit, it freezes in the small hole of the expansion valve and blocks
the refrigerant flow to cause a cooling trouble.

80-14 PC45MR-5, PC55MR-5

80 APPENDIX AIR CONDITIONER UNIT

COMPONENT PARTS OF AIR CONDITIONER SYSTEM

AIR CONDITIONER UNIT
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT

PC45MR-5, PC55MR-5 80-15

AIR CONDITIONER UNIT 80 APPENDIX

1: Expansion valve 4: Heater core

2: Evaporator temperature sensor 5: FRESH/RECIRC air changeover door
3: Evaporator 6: Blower motor
REMARK
“Door” may be expressed as “damper”.

80-16 PC45MR-5, PC55MR-5

80 APPENDIX COMPRESSOR

COMPRESSOR
STRUCTURE OF COMPRESSOR
General view

A: Refrigerant inlet (from air conditioner unit) B: Refrigerant outlet (to condenser)
1: Pulley 2: Magnetic clutch

SPECIFICATIONS OF COMPRESSOR
Number of cylinders - Cylinder bore x Stroke: : 7-25.4×28.1 mm
Delivery: : 99.8 cc/rev
Allowable max. speed: : 6500 rpm
Compressor oil: SANDEN: ND-OIL8 (for R134a)
Compressor oil quantity: : 100 cc

FUNCTION OF COMPRESSOR
• The compressor circulates the refrigerant and compresses the gaseous refrigerant from the evaporator into
a misty refrigerant at high pressure and high temperature so that it is easily regenerated (liquefied) at the
normal temperature.

PC45MR-5, PC55MR-5 80-17

COMPRESSOR 80 APPENDIX

• The air conditioner controller operates magnetic clutch (2) inside the compressor, according to the evapora-
tor temperature and refrigerant pressure.
• When magnetic clutch (2) is engaged, the compressor shaft is turned together with pulley (1) by the engine
power, and the compressor is driven.

80-18 PC45MR-5, PC55MR-5

80 APPENDIX CONDENSER

CONDENSER
STRUCTURE OF CONDENSER
General view

A: Refrigerant inlet (from compressor) B: Refrigerant outlet (to receiver drier)

SPECIFICATIONS OF CONDENSER
Fin pitch: 9.5 mm
Height x Width x thickness: 370.5×283.4×25 mm
Max. operating pressure: 3.53 MPa {36 kg/cm2}

FUNCTION OF CONDENSER
Condenser cools and liquefies the high-pressure high-temperature misty refrigerant sent from the compressor.
NOTICE
• If the cooling fins are crushed or clogged with dirt, etc., the heat exchanged efficiency decreases
and the refrigerant cannot be completely liquefied.
• If the heat exchange efficiency decreases, the circuit pressure in the refrigerant cycle increases re-
sulting in unnecessary load on the engine and poor cooling effect. Be careful not to crush the fins in
handling and daily maintenance of the condenser.

PC45MR-5, PC55MR-5 80-19

RECEIVER DRIER 80 APPENDIX

RECEIVER DRIER
STRUCTURE OF RECEIVER DRIER
General view and sectional view

A: Refrigerant inlet (from condenser) B: Refrigerant outlet (to air conditioner unit)

SPECIFICATIONS OF RECEIVER DRIER

Effective capacity: : 240 cc
Weight of desiccating agent: : 100 g

FUNCTION OF RECEIVER DRIER

• The receiver drier temporarily stores the high pressure and high temperature liquid refrigerant from the con-
denser so that it can be supplied to the evaporator corresponding to the need of cooling.
• Even if bubbles are mixed in the refrigerant, depending on the heat radiation condition of the condenser, the
refrigerant can be liquefied perfectly by sending out the accumulated refrigerant from the bottom to the
evaporator.
• The built-in filter and desiccating agent remove foreign material in the circulation circuit and moisture con-
tained in the refrigerant.

80-20 PC45MR-5, PC55MR-5

80 APPENDIX INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE

INFORMATION DESCRIBED IN TROUBLESHOOTING TA-

BLE
The following types of information are described in the troubleshooting table and related circuit diagram. Fully
understand the description and perform troubleshooting.
Failure Problem on machine
Related information Information related to the occurred failure and its troubleshooting

No. Cause Procedure, measuring location, criteria, and remarks

1 Probable causes for [Details]
2 trouble • Procedure
• Measuring point
"Between A and B" denotes measuring values such as voltage and resist-
ance, etc. between A and B.
• Criteria to judge probable causes (standard value), remarks
[Precautions for troubleshooting]
(1) Connector number description sequence and tester lead handling
3 Defective --- For troubleshooting, connect the positive (+) and negative (-) leads of a multimeter as
shown below unless otherwise specified.
• Connect the positive (+) lead to pin or wiring harness indicated in the front.
• Connect the negative (-) lead to a pin or wiring harness indicated in the rear.
(2) Example of troubleshooting by check of multiple items
• Normal in 1 but abnormal in 2
At that time, the description is made as "Defective ---" as shown on the left.

[Failures in wiring harness]

• Open circuit
Connection of connector is defective or wiring harness is broken.
• Ground fault
A wiring harness not to be connected to the GND (ground) circuit comes to contact with the GND (ground)
circuit or chassis.
• Hot short circuit
A wiring harness not to be connected to the power supply circuit comes to contact with the power supply
circuit.
• Short circuit
An independent wire in the wiring harness abnormally comes into contact with one of other wires. (Defec-
tive insulation in connector, etc.)

PC45MR-5, PC55MR-5 80-21

INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 80 APPENDIX

Related circuit diagram

This is the excerpted circuit diagram related to troubleshooting
• Connector numbers and pin numbers are shown.
• Size of wire is shown. When there is a number in front of color, it shows size.
W: White, B: Black, R: Red, G: Green, Y: Yellow, L: Blue, V: Purple, P: Pink, O: Orange, Br: Brown, Gr:
Gray, Sb: Sky blue, Lg: Light green, Dg: Dark green, Ch: Dark brown
• When there are two colors
Example) WY: Yellow line on white background
• When there is a number in front of color, it shows size.
• NC: Normally closed (Normally ON)
• [1] and [2] are numbers of unlabeled connectors.
• Arrow (←→): Roughly indicates their mounting place on the machine.

80-22 PC45MR-5, PC55MR-5

A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CON-
80 APPENDIX DITIONER DOES NOT OPERATE)

A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM

(AIR CONDITIONER DOES NOT OPERATE)
Failure Air conditioner does not operate.
• Check in advance that fuse is not blown out and continuity of wiring harness between
each connectors is normal.
Related • When air flow selector switch (blower switch) is turned on (position 1, 2, or 3), air condi-
information tioner switch is ON.
• If air does not come out, perform check for “Troubleshooting of blower motor system (air
does not come out or air flow is abnormal)” first.

No. Cause Procedure, measuring location, criteria and remarks

PC45MR-5, PC55MR-5 80-23

A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CON-
DITIONER DOES NOT OPERATE) 80 APPENDIX

Circuit diagram related to air conditioner power supply

80-24 PC45MR-5, PC55MR-5

A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CON-
80 APPENDIX DITIONER DOES NOT OPERATE)

PC45MR-5, PC55MR-5 80-25

A-2 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR
COMES OUT OR AIR FLOW IS ABNORMAL) 80 APPENDIX

A-2 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM

(NO AIR COMES OUT OR AIR FLOW IS ABNORMAL)
Failure No air comes out or air flow cannot be selected.
Related Check in advance that fuse is not blown out and continuity of wiring harness between each connec-
information tors is normal.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect connector [13].
Between [13] (switch side) Airflow selector switch:
Min. 1 MΩ
B and L/R OFF
Between [13] (switch side) Airflow selector switch:
Min. 1 MΩ
B and L/Y OFF
Between [13] (switch side) Airflow selector switch:
Min. 1 MΩ
B and L/B OFF
Between [13] (switch side) Airflow selector switch:
Min. 1 MΩ
B and L/W OFF
Between [13] (switch side)
Airflow selector switch: 1 Max. 1 Ω
B and L/R
Between [13] (switch side)
Airflow selector switch: 1 Max. 1 Ω
Defective air flow selec- B and L/W
1
tor switch (blower switch)
Between terminals other
Resistance Airflow selector switch: 1 Min. 1 MΩ
than above
Between [13] (switch side)
Airflow selector switch: 2 Max. 1 Ω
B and L/R
Between [13] (switch side)
Airflow selector switch: 2 Max. 1 Ω
B and L/Y
Between terminals other
Airflow selector switch: 2 Min. 1 MΩ
than above
Between [13] (switch side)
Airflow selector switch: 3 Max. 1 Ω
B and L/R
Between [13] (switch side)
Airflow selector switch: 3 Max. 1 Ω
B and L/B
Between terminals other
Airflow selector switch: 3 Min. 1 MΩ
than above
1. Turn the starting switch to OFF position.
2. Disconnect connector [12].

2 Defective resistor Approx.

Between [12] (air conditioner unit side) L/W and L/Y
1.8 Ω
Resistance
Approx.
Between [12] (air conditioner unit side) L/B and L/Y
0.7 Ω
1. Turn the starting switch to OFF position.
2. Disconnect connector [12].
3 Defective blower motor Continuity Between [12] (air conditioner unit side) W/G and L/B Continuity
Between [12] (air conditioner unit side) W/G and
Resistance Min. 1 MΩ
ground

80-26 PC45MR-5, PC55MR-5

A-2 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR
80 APPENDIX COMES OUT OR AIR FLOW IS ABNORMAL)

No. Cause Procedure, measuring location, criteria and remarks

Be ready with starting switch in OFF position, then perform troubleshooting with
Open circuit in wiring har- starting switch stayed in OFF position.
4 ness (wire breakage or
defective connector) Check the continuity between each connectors by re-
Resistance Max. 1 Ω
ferring to circuit diagram.
Be ready with starting switch in OFF position, then perform troubleshooting with
Ground fault in wiring starting switch stayed in OFF position.
5 harness (contact with Check the insulation between each connector and
ground circuit) Resistance ground (excluding ground circuit) by referring to circuit Min. 1 MΩ
diagram.
Defective control amplifi- If no failure is found by preceding checks, controller amplifier is defective.
6
er

PC45MR-5, PC55MR-5 80-27

A-2 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR
COMES OUT OR AIR FLOW IS ABNORMAL) 80 APPENDIX

Circuit diagram related to blower motor system

80-28 PC45MR-5, PC55MR-5

A-2 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR
80 APPENDIX COMES OUT OR AIR FLOW IS ABNORMAL)

PC45MR-5, PC55MR-5 80-29

A-3 TROUBLESHOOTING FOR TEMPERATURE CONTROL FUNC-
TION 80 APPENDIX

A-3 TROUBLESHOOTING FOR TEMPERATURE CONTROL

FUNCTION
Failure Vent temperature cannot be adjusted.
• Check in advance that hot water flows to inlet side of hot water cut valve.
Related
• Check in advance that fuse is not blown out and continuity of wiring harness between
information
each connectors is normal.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect connector [3].
Approx.
Dial control: COOL-MAX 2.3 kΩ →
Between [3] (switch side) → MEDIUM position 1 Ω and be-
Y/W and Y/B low
Defective temperature Dial control: MEDIUM po-
1 Max. 1 Ω
control switch sition → HOT-MAX
Resistance
Dial control: COOL-MAX Approx.
→ MEDIUM position 2.3 kΩ
Between [3] (switch side) Approx.
Y/W and G/W Dial control: MEDIUM po- 2.3 kΩ →
sition → HOT-MAX 1 Ω and be-
low
1. Turn the starting switch to OFF position.
2. Remove the cover of air conditioner unit, and start the engine.
Defective hot water cut 3. Turn on the blower switch (any of 1, 2, and 3)
2
valve assembly 4. Operate the temperature control switch.
If the rod does not move in accordance with the operation of temperature control
switch, hot water cut valve assembly is defective.
Be ready with starting switch in OFF position, then perform troubleshooting with
Open circuit in wiring har- starting switch stayed in OFF position.
3
ness Check the continuity between each connectors by re-
Resistance Max. 1 Ω
ferring to circuit diagram.
Be ready with starting switch in OFF position, then perform troubleshooting with
starting switch stayed in OFF position.
Short circuit in wiring har-
4 Check the insulation between each connector and
ness
Resistance ground (excluding ground circuit) by referring to circuit Min. 1 MΩ
diagram.
Defective control amplifi- If no failure is found by preceding checks, controller amplifier is defective.
5
er

80-30 PC45MR-5, PC55MR-5

A-3 TROUBLESHOOTING FOR TEMPERATURE CONTROL FUNC-
80 APPENDIX TION

Circuit diagram related to temperature control function

PC45MR-5, PC55MR-5 80-31

A-3 TROUBLESHOOTING FOR TEMPERATURE CONTROL FUNC-
TION 80 APPENDIX

80-32 PC45MR-5, PC55MR-5

A-4 TROUBLESHOOTING FOR AIR CONDITINOER COMPRESSOR
80 APPENDIX AND COOLING SYSTEM (ELECTRICAL SYSTEM)

A-4 TROUBLESHOOTING FOR AIR CONDITINOER COM-

PRESSOR AND COOLING SYSTEM (ELECTRICAL SYS-
TEM)
Failure Air is not cooled or temperature cannot be adjusted.
• When outside air temperature is 2 °C and below, this phenomenon is not abnormal.
Related
• Check in advance that fuse is not blown out and continuity of wiring harness between
information
each connectors is normal.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect connector [13].
REMARK
Defective air conditioner
1 There are 2 each of G and L/R, check by referring to circuit diagram.
switch
Air conditioner switch: ON Max. 1 Ω
Between [13] (switch side)
Resistance Air conditioner switch:
G and L/R Min. 1 MΩ
OFF
1. Turn the starting switch to OFF position.
Defective compressor 2.
2 Disconnect connector M13.
clutch
Voltage Between M13 (male) and ground 10 to 15 V
1. Turn the starting switch to OFF position.
Defective refrigerant (du- 2.
3 Disconnect connector [5].
al) pressure switch
Resistance [5] Between terminals (switch side terminal) Max. 1 Ω
1. Turn the starting switch to OFF position.
2. Disconnect connector [4].
Approx.
Between [4] (relay side) R/B and Br
320 Ω
Defective compressor re-
4 When power supply volt-
lay Between [4] (relay side) R
age is added between [4] Max. 1 Ω
Resistance and R/G
R/B and Br
When power supply volt-
Between [4] (relay side) R
age is not added between Min. 1 MΩ
and R/G
[4] R/B and Br
1. Turn the starting switch to OFF position.
2. Disconnect connector [12].
Defective evaporator Approx.
5 0 °C
temperature sensor Between [12] (air condi- 7.2 kΩ
Resistance tioner unit side) B/W and
B/R Approx.
25 °C
2.2 kΩ
Be ready with starting switch in OFF position, then perform troubleshooting with
Open circuit in wiring har- starting switch stayed in OFF position.
6
ness Check the continuity between each connectors by re-
Resistance Max. 1 Ω
ferring to circuit diagram.

PC45MR-5, PC55MR-5 80-33

A-4 TROUBLESHOOTING FOR AIR CONDITINOER COMPRESSOR
AND COOLING SYSTEM (ELECTRICAL SYSTEM) 80 APPENDIX

No. Cause Procedure, measuring location, criteria and remarks

Be ready with starting switch in OFF position, then perform troubleshooting with
Ground fault in wiring starting switch stayed in OFF position.
7 harness (contact with Check the insulation between each connector and
ground circuit) Resistance ground (excluding ground circuit) by referring to circuit Min. 1 MΩ
diagram.
Defective control amplifi- If no failure is found by preceding checks, controller amplifier is defective.
8
er

80-34 PC45MR-5, PC55MR-5

A-4 TROUBLESHOOTING FOR AIR CONDITINOER COMPRESSOR
80 APPENDIX AND COOLING SYSTEM (ELECTRICAL SYSTEM)

Circuit diagram related to compressor and refrigerant system

PC45MR-5, PC55MR-5 80-35

A-4 TROUBLESHOOTING FOR AIR CONDITINOER COMPRESSOR
AND COOLING SYSTEM (ELECTRICAL SYSTEM) 80 APPENDIX

80-36 PC45MR-5, PC55MR-5

A-5 TROUBLESHOOTING FOR AIR CONDITINOER COMPRESSOR
80 APPENDIX AND COOLING SYSTEM (MECHANICAL SYSTEMS)

A-5 TROUBLESHOOTING FOR AIR CONDITINOER COM-

PRESSOR AND COOLING SYSTEM (MECHANICAL SYS-
TEMS)
Failure Air is not cooled or temperature cannot be adjusted.
Related
information

No. Cause Procedure, measuring location, criteria and remarks

Gas leakage from pipe Check it and if any trouble is found, repair or replace it.
1
joint and parts
Leakage from hose, etc. Check whether refrigerant level is correct, and if it is insufficient, refill with it to the
2 (refrigerant has not been specified level.
refilled for long-term)
3 Insufficient refrigerant Refill with refrigerant to the specified level.
Defective expansion Check it and if any trouble is found, repair or replace it.
4
valve
Clogging of low-pressure Check it and if it is clogged, remove the stuffing or replace it.
5
circuit or evaporator
6 Clogged evaporator fin Check it and if it is clogged, clean the evaporator.
7 Clogged filter Check it and clean or replace.
Defective installment of Check it and if any trouble is found, repair or replace it.
8 evaporator temperature
sensor
Air leakage from air con- Check it and repair or replace air leakage part.
9 ditioner unit and duct
joint
10 Lack of set air flow Increase the set air flow.
Over-filling with refriger- Check whether refrigerant level is correct, and if it is too much, extract it to the
11
ant specified level.
After evacuation, refill with refrigerant to the specified level, and replace the receiv-
12 Mixing of air
er drier.
13 Clogged condenser fin Check it and if it is clogged, clean the fin.
Defective compression of Check it and if any trouble is found, repair or replace it.
14
compressor
Mixing of moisture in re- After evacuation, refill with refrigerant to the specified level, and replace the receiv-
15
frigerant circuit er drier.

PC45MR-5, PC55MR-5 80-37

A-6 TROUBLESHOOTING FOR HOT WATER CIRCUIT SYSTEM 80 APPENDIX

A-6 TROUBLESHOOTING FOR HOT WATER CIRCUIT

SYSTEM
• Heating trouble
Failure
• Defective temperature control
Related • Check the hot water circuit for water leakage.
information • Check that air flows out of the vent.

No. Cause Procedure, measuring location, criteria and remarks

Check it and if it is clogged, clean the heater core fin.
REMARK
1 Clogged heater core fins
If this item is the cause, temperature at hot water inlet and outlet of heater core
becomes high.
Check it and repair or replace air leakage part.
Air leakage from air con- REMARK
2
ditioner unit If this item is the cause, temperature at hot water inlet and outlet of heater core
becomes high.
Check it and if it is clogged or valve is defective, remove the stuffing or replace it.
Defective hot water cut REMARK
3 valve (clogging or defec-
tive valve) If this item is the cause, temperature at hot water inlet of heater core becomes
high and that at hot water outlet becomes low.
Check it and repair or replace clogging part.
Clogged heater core in- REMARK
4
side If this item is the cause, temperature at hot water inlet of heater core becomes
high and that at hot water outlet becomes low.
Check it and repair or replace clogging part.
Clogging up to hot water REMARK
5
inlet of heater core If this item is the cause, temperature at hot water inlet of heater core becomes
low.

80-38 PC45MR-5, PC55MR-5

A-7 UNUSUAL NOISE IS HEARD FROM AIR CONDITINOER RELATED
80 APPENDIX PARTS

A-7 UNUSUAL NOISE IS HEARD FROM AIR CONDITINO-

ER RELATED PARTS
Failure Unusual noise is heard.
Related
information

No. Cause Procedure, measuring location, criteria and remarks

Defective installment of Check it and if any trouble is found, repair it.
1
case related bolt (screw)
Interference of fan case Check it and if any trouble is found, repair or replace it.
2
or broken fan
Foreign material in blow- Check it and if any trouble is found, remove foreign material and repair or replace
3 er motor or defective it.
blower motor
Defective expansion Check it and if unusual noise (gas leaking sound) is heard, replace it.
4
valve
Looseness or wear of Check it and if looseness or wear is found, repair or replace it.
5
compressor V-belt
Over-filling or short-filling Check whether refrigerant level is correct, and if it is insufficient or too much, adjust
6
with refrigerant it to the specified level.
7 Defective compressor Check it and if any trouble is found, repair or replace it.

PC45MR-5, PC55MR-5 80-39

A-8 WATER LEAKS FROM AIR CONDITINOER RELATED PARTS 80 APPENDIX

A-8 WATER LEAKS FROM AIR CONDITINOER RELATED

PARTS
Failure There is water leakage.
Related
information

No. Cause Procedure, measuring location, criteria and remarks

Clogged water drainage Check it and if any trouble is found, repair it.
1
port of air conditioner unit
Clogging, kinking, holing, Check it and if any trouble is found, repair or replace it.
or defective installation of
2
drain hose of air condi-
tioner unit
Crack of air conditioner Check it and if any crack is found, repair it.
3
unit case
Defective mounting bolt Check it and if any trouble is found, repair or replace it.
4 (screw) related to air con-
ditioner unit case
Defective connection of Check it and if any trouble is found, repair or replace it.
5
pipe in hot water circuit
6 Defective heater core Check it and if any trouble is found, repair or replace it.
Defective hot water cut Check it and if any trouble is found, repair or replace it.
7
valve

80-40 PC45MR-5, PC55MR-5

80 APPENDIX A-9 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER

A-9 TROUBLESHOOTING FOR FRESH/RECIRC AIR

CHANGEOVER
Failure Fresh air and recirculation air cannot be changed over.
Related
information

No. Cause Procedure, measuring location, criteria and remarks

Defective FRESH/ Check it and if any trouble is found, clean and repair or replace it.
1 RECIRC air changeover
lever
Malfunction of intake Check it and if any trouble is found, clean and repair or replace it.
2
damper
Clogged unit fresh air in- Check it and if any trouble is found, clean it.
3 let duct with foreign ma-
terial

PC45MR-5, PC55MR-5 80-41

PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES
AND TUBES IN AIR CONDITIONER PIPINGS 80 APPENDIX

PRECAUTIONS FOR DISCONNECTING AND CONNECT-

ING HOSES AND TUBES IN AIR CONDITIONER PIPINGS
Precautions for disconnection
k When replacing the air conditioner unit, compressor, condenser or receiver drier, etc., collect the re-
frigerant (air conditioner gas: R134a) from the air conditioner circuit before disconnecting the air
conditioner hoses.
k If refrigerant gas (air conditioner gas: R134a) gets in your eyes, you may lose your sight. And if it
touches your skin, you may suffer from frostbite. Put on protective eyeglasses, gloves and working
clothes with long sleeves while collecting the refrigerant or filling the air conditioner circuit with the
refrigerant.
NOTICE
• Never release the refrigerant (air conditioner gas: R134a) to the atmosphere.
• Ask a qualified person for collecting, adding and filling operations of the refrigerant (air conditioner
gas: R134a).

1: Engine 4: Receiver drier

2: Compressor 5: Air conditioner unit
3: Condenser
• When loosening the air conditioner hose nut after collecting the refrigerant, be sure to use 2 wrenches. Use
one wrench to fix one nut and the other wrench to loosen the other nut.
• When working on the air conditioner piping, take measures to prevent the entry of dirt, dust, water, etc. into
the hoses.
Precautions for connection
• When connecting the pipes, apply compressor oil(SP-10) for R134a to prevent O-ring from damage and
twisting.

80-42 PC45MR-5, PC55MR-5

PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES
80 APPENDIX AND TUBES IN AIR CONDITIONER PIPINGS

Do not apply oil to threaded portion of bolt, nut and union.

• Once an O-ring is used, it is deformed and deteriorated.
Accordingly, do not reuse it. When removing it, use a soft
tool (such as a toothpick) so that the piping will not be
damaged.
• When connecting a pipe, push it into the end and fully fin-
ger-tighten the bolt or nut.
• Be sure to use 2 wrenches (torque wrench for tightening
side) to tighten each nut. Use one wrench to fix one nut
and the other wrench to tighten the other nut to the speci-
fied torque.
REMARK
An O-ring is fitted to every joint of the air conditioner piping.

Table of tightening torque for refrigerant pipe joint.

Thread size Tightening torque
M6 x 1.0 8 to 12 Nm {0.8 to 1.2 kgm}
M8 x 1.25 20 to 25 Nm {2.0 to 2.6 kgm}

PC45MR-5, PC55MR-5 80-43

HANDLE COMPRESSOR OIL 80 APPENDIX

HANDLE COMPRESSOR OIL

Management of compressor oil (SANDEN: SP-10 for R134a)
The compressor oil does not need to be checked or refilled as frequently as the engine oil. However, if its level
is low or too high, it can cause the following troubles. Accordingly, charge the compressor oil by the specified
quantity, similarly to the refrigerant.
Condition Content
Lack of oil Defective lubrication and seizure of compressor
Defective cooling (Excess oil sticks to each part and decreases heat ex-
Excess of oil
change efficiency)

Refilling with compressor oil

k Refrigerant is potentially hazardous to health and environment. Before disconnecting air conditioner
hoses, collect refrigerant according to “PRECAUTIONS FOR DISCONNECTING AND CONNECTING
HOSES AND TUBES IN AIR CONDITIONER PIPINGS”.
k If oil for CFC-12 (R-12) is used, lubrication trouble will occur and the compressor may be broken or
seized.
Be sure to use oil for R134a (SANDEN: SP-10).
k Since oil for R134a is extremely hygroscopic, cap the oil container immediately after use in order to
limit contact with air.
Store the oil container in a dry and well ventilated place.
k Since the compressor oil may dissolve the plastic and painting surface, do not allow the oil to con-
tact with them.
Check in the following cases, and add new oil as necessary.
• The large quantity of leakage of refrigerant occurs and refrigerant is discharged abruptly.
• The compressor is replaced due to a failure.
(See "The quantity of compressor oil when the compressor is replaced".)
• Cycle parts such as the condenser, receiver drier, evaporator unit, etc. are replaced.
The quantity of compressor oil when the compressor is replaced
The following is the explanation of the quantity of compressor oil when the compressor is broken due to seizure,
etc. and in other cases.
• When compressor is broken due to seizure, etc.
Metal chips circulate in the air conditioner circuit and contaminate the compressor oil remarkably.
In such case, clean the air conditioner circuit and replace the compressor and receiver drier.
Since all of the compressor oil is drained from the air conditioner circuit by cleaning the circuit, install the
new compressor together with the filled oil of the specified quantity (100 cc).
• In other cases
New compressor contains compressor oil of 100 cc in it.
1. Prepare a container to catch the oil, and drain the oil
from the removed compressor.
2. Measure the quantity of the drained oil with a measur-
ing cylinder, and write it down.
3. Drain the oil from the new compressor by the following
quantity.
Quantity to be drained = 100 cc - "Quantity written
down"
Example: If 30 cc is drained from the removed com-
pressor, the quantity to be drained from the new com-
pressor will be 70 cc (= 100 cc - 30 cc).

80-44 PC45MR-5, PC55MR-5

90 CIRCUIT DIAGRAMS

S/T
Steering
STRG
SIG Signal
SOL Solenoid
STD Standard
OPT
Option
OP
PRESS Pressure
SPEC Specification
SW Switch
TEMP Temperature
T/C Torque Converter
T/M Transmission

90-8 PC45MR-5, PC55MR-5

90 CIRCUIT DIAGRAMS SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM

HYDRAULIC CIRCUIT DIAGRAM

SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM
Symbol Content

Main piping route

Pilot and drain route

Flexible piping such as hose

Crossing of disconnected route

Connected route

Flow of fluid

Throttle

Variable

Electric

Spring

Pickup port

Pickup port and pressure gauge

PC45MR-5, PC55MR-5 90-9

SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM 90 CIRCUIT DIAGRAMS

Symbol Content

Check valve

Intake port (with strainer)

Tank and return piping

Filter

Oil cooler

Stop valve

Drive shaft (1 way)

Drive shaft (reversible)

Hydraulic pump
Reference: ▲ in the figure shows outlet

Variable displacement hydraulic pump

Hydraulic motor
Reference: ▲ and ▼ in the figure show the direction of oil flow into hydraulic
motor, and as direction changes, the rotation of motor is reversed.

Servo piston

PPC valve

90-10 PC45MR-5, PC55MR-5

90 CIRCUIT DIAGRAMS SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM

Symbol Content

Control valve

Single acting solenoid valve

Single acting proportional solenoid valve

Hydraulic pilot valve

Hydraulic 2-stage pilot valve

Lock valve

Drain valve

Pressure regulating valve, safety valve, relief valve

(when the oil pressure is discharged to the low-pressure side)

Bypass valve

Accumulator

Cylinder

Cylinder with piston valve

PC45MR-5, PC55MR-5 90-11

SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM 90 CIRCUIT DIAGRAMS

Symbol Content

Unit

90-12 PC45MR-5, PC55MR-5

HYDRAULIC CIRCUIT DIAGRAM
PC45MR-5, PC55MR-5
REMARK
This figure covers the equipment and devices that are unavailable as optional items in some areas.

PC45MR-5, PC55MR-5 90-13

HYDRAULIC CIRCUIT DIAGRAM (QUICK COUPLER SPECIFICATIONS) (1/2)
PC45MR-5, PC55MR-5
REMARK
This figure covers the equipment and devices that are unavailable as optional items in some areas.

PC45MR-5, PC55MR-5 90-15

HYDRAULIC CIRCUIT DIAGRAM (QUICK COUPLER SPECIFICATIONS) (2/2)
PC45MR-5, PC55MR-5
REMARK
This figure covers the equipment and devices that are unavailable as optional items in some areas.

PC45MR-5, PC55MR-5 90-17

SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM

ELECTRICAL CIRCUIT DIAGRAM

SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM
Symbol Content

Wire

Wire (junction disconnected)

Wire (junction connected)

Combined wire

Terminal

Grounding by chassis ground

Grounding by terminal

Variable

Resistor

Variable resistor

Diode

Light emitting diode (LED)

Photo diode

Low-voltage diode (Zener diode)

Transistor (PNP type)

Transistor (NPN type)

Electromagnetic coil

Battery

Fuse

90-20 PC45MR-5, PC55MR-5

SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM

Symbol Content
Connector
Reference:
• Concave side of contact face (left in the figure): Female
• Convex side of contact face (right in the figure): Male
REMARK
Figure shows the disconnected state.
Plug type connector (left: male, right: female)
REMARK
Figure shows the connected state.

Solenoid

Motor

Lamp

Pressure switch (N.O. type)

N.O.: Normally Open

Pressure switch (N.C. type)

N.C.: Normally Closed

Potentiometer, fuel control dial

Temperature sensor

Starting switch

Backup alarm

Horn

PC45MR-5, PC55MR-5 90-21

SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM

Symbol Content

Buzzer

Antenna

90-22 PC45MR-5, PC55MR-5

ELECTRICAL CIRCUIT DIAGRAM (CANOPY SPEC) (1/5)
PC45MR-5, PC55MR-5
REMARK
This figure covers the equipment and devices that are unavailable as optional items in some areas.

PC45MR-5, PC55MR-5 90-23

ELECTRICAL CIRCUIT DIAGRAM (CANOPY SPEC) (2/5)
PC45MR-5, PC55MR-5
REMARK
This figure covers the equipment and devices that are unavailable as optional items in some areas.

PC45MR-5, PC55MR-5 90-25

ELECTRICAL CIRCUIT DIAGRAM (CANOPY SPEC) (3/5)
PC45MR-5, PC55MR-5
REMARK
This figure covers the equipment and devices that are unavailable as optional items in some areas.

PC45MR-5, PC55MR-5 90-27

ELECTRICAL CIRCUIT DIAGRAM (CANOPY SPEC) (4/5)
PC45MR-5, PC55MR-5
REMARK
This figure covers the equipment and devices that are unavailable as optional items in some areas.

PC45MR-5, PC55MR-5 90-29

ELECTRICAL CIRCUIT DIAGRAM (CANOPY SPECIFICATIONS, QUICK COUPLER SPECIFICATIONS) (1/5)
PC45MR-5, PC55MR-5
REMARK
This figure covers the equipment and devices that are unavailable as optional items in some areas.

PC45MR-5, PC55MR-5 90-33

ELECTRICAL CIRCUIT DIAGRAM (CANOPY SPECIFICATIONS, QUICK COUPLER SPECIFICATIONS) (2/5)
PC45MR-5, PC55MR-5
REMARK
This figure covers the equipment and devices that are unavailable as optional items in some areas.

PC45MR-5, PC55MR-5 90-35

ELECTRICAL CIRCUIT DIAGRAM (CANOPY SPECIFICATIONS, QUICK COUPLER SPECIFICATIONS) (3/5)
PC45MR-5, PC55MR-5
REMARK
This figure covers the equipment and devices that are unavailable as optional items in some areas.

PC45MR-5, PC55MR-5 90-37

ELECTRICAL CIRCUIT DIAGRAM (CANOPY SPECIFICATIONS, QUICK COUPLER SPECIFICATIONS) (4/5)
PC45MR-5, PC55MR-5
REMARK
This figure covers the equipment and devices that are unavailable as optional items in some areas.

PC45MR-5, PC55MR-5 90-39

ELECTRICAL CIRCUIT DIAGRAM (CANOPY SPECIFICATIONS, QUICK COUPLER SPECIFICATIONS) (5/5)
PC45MR-5, PC55MR-5
REMARK
This figure covers the equipment and devices that are unavailable as optional items in some areas.

PC45MR-5, PC55MR-5 90-41

ELECTRICAL CIRCUIT DIAGRAM (CAB SPEC) (1/6)
PC45MR-5, PC55MR-5
REMARK
This figure covers the equipment and devices that are unavailable as optional items in some areas.

PC45MR-5, PC55MR-5 90-43

ELECTRICAL CIRCUIT DIAGRAM (CAB SPEC) (2/6)
PC45MR-5, PC55MR-5
REMARK
This figure covers the equipment and devices that are unavailable as optional items in some areas.

PC45MR-5, PC55MR-5 90-45

ELECTRICAL CIRCUIT DIAGRAM (CAB SPEC) (3/6)
PC45MR-5, PC55MR-5
REMARK
This figure covers the equipment and devices that are unavailable as optional items in some areas.

PC45MR-5, PC55MR-5 90-47

ELECTRICAL CIRCUIT DIAGRAM (CAB SPEC) (4/6)
PC45MR-5, PC55MR-5
REMARK
This figure covers the equipment and devices that are unavailable as optional items in some areas.

PC45MR-5, PC55MR-5 90-49

ELECTRICAL CIRCUIT DIAGRAM (CAB SPEC) (5/6)
PC45MR-5, PC55MR-5
REMARK
This figure covers the equipment and devices that are unavailable as optional items in some areas.

PC45MR-5, PC55MR-5 90-51

ELECTRICAL CIRCUIT DIAGRAM (CAB SPEC) (6/6)
PC45MR-5, PC55MR-5
REMARK
This figure covers the equipment and devices that are unavailable as optional items in some areas.

PC45MR-5, PC55MR-5 90-53

ELECTRICAL CIRCUIT DIAGRAM (CAB SPECIFICATIONS, QUICK COUPLER SPECIFICATIONS) (1/6)
PC45MR-5, PC55MR-5
REMARK
This figure covers the equipment and devices that are unavailable as optional items in some areas.

PC45MR-5, PC55MR-5 90-55

ELECTRICAL CIRCUIT DIAGRAM (CAB SPECIFICATIONS, QUICK COUPLER SPECIFICATIONS) (2/6)
PC45MR-5, PC55MR-5
REMARK
This figure covers the equipment and devices that are unavailable as optional items in some areas.

PC45MR-5, PC55MR-5 90-57

ELECTRICAL CIRCUIT DIAGRAM (CAB SPECIFICATIONS, QUICK COUPLER SPECIFICATIONS) (3/6)
PC45MR-5, PC55MR-5
REMARK
This figure covers the equipment and devices that are unavailable as optional items in some areas.

PC45MR-5, PC55MR-5 90-59

ELECTRICAL CIRCUIT DIAGRAM (CAB SPECIFICATIONS, QUICK COUPLER SPECIFICATIONS) (4/6)
PC45MR-5, PC55MR-5
REMARK
This figure covers the equipment and devices that are unavailable as optional items in some areas.

PC45MR-5, PC55MR-5 90-61

ELECTRICAL CIRCUIT DIAGRAM (CAB SPECIFICATIONS, QUICK COUPLER SPECIFICATIONS) (5/6)
PC45MR-5, PC55MR-5
REMARK
This figure covers the equipment and devices that are unavailable as optional items in some areas.

PC45MR-5, PC55MR-5 90-63

ELECTRICAL CIRCUIT DIAGRAM (CAB SPECIFICATIONS, QUICK COUPLER SPECIFICATIONS) (6/6)
PC45MR-5, PC55MR-5
REMARK
This figure covers the equipment and devices that are unavailable as optional items in some areas.

PC45MR-5, PC55MR-5 90-65

INDEX

INDEX
A Arm cylinder - Test by isolating the part causing hy-
draulic drift................................................... 30-85
A-1 Troubleshooting for power supply system (air Arm cylinder - Test oil leakage............................ 30-87
conditioner does not operate)...................... 80-23 Arm - Dimension................................................. 60-63
A-2 Troubleshooting for blower motor system (no air Assembly and disassembly - Related information.......
comes out or air flow is abnormal)...............80-26 ..................................................................... 50-11
A-3 Troubleshooting for temperature control function.. Attachment PPC valve...................................... 10-134
.....................................................................80-30 Attachment PPC valve - Maintenance standard. 60-54
A-4 TROUBLESHOOTING FOR AIR CONDITINOER Attachment PPC valve - Structure.................... 10-134
COMPRESSOR AND COOLING SYSTEM Auto-deceleration system................................... 10-20
(ELECTRICAL SYSTEM)............................ 80-33 Auto-deceleration system - Operation................ 10-21
A-5 TROUBLESHOOTING FOR AIR CONDITINOER Auto-decelerator system - System diagram........10-20
COMPRESSOR AND COOLING SYSTEM (ME- Automatic gear shift valve of travel motor - Operation.
CHANICAL SYSTEMS)............................... 80-37 ...................................................................10-166
A-6 TROUBLESHOOTING FOR HOT WATER CIR- Automatic idle stop system................................. 10-24
CUIT SYSTEM.............................................80-38 Automatic idle stop - System diagram................ 10-24
A-7 UNUSUAL NOISE IS HEARD FROM AIR CON- Automatic idle stop system - Function................ 10-24
DITIONER RELATED PARTS......................80-39
A-8 WATER LEAKS FROM AIR CONDITIONER RE- B
LATED PARTS.............................................80-40
A-9 Troubleshooting for fresh/recirc air changeover.... Batery disconnect switch.................................... 10-14
.....................................................................80-41 Battery disconnect setting - Operate.................30-149
Abbreviation List........................................................... Battery disconnect switch - Function.................. 10-14
...........00-11,01-3,10-4,20-3,30-5,40-6,50-5,60-3, Bipartite solenoid valve..................................... 10-140
80-3,90-3 Bipartite solenoid valve - Structure................... 10-140
Abnormality record (Electrical Sys Abnormality Re- Blade - Adjust LOWER relief pressure................30-59
cord) - Confirm...........................................30-123 Blade cylinder - Maintenance standard...............60-73
Abnormality record (Mechanical systems) - Confirm... Blade cylinder - Test oil leakage......................... 30-88
...................................................................30-122 Blade PPC valve............................................... 10-136
Abnormality Record Menu................................ 30-122 Blade PPC valve - Maintenance standard.......... 60-47
Accumulator assembly - Install............. 50-127,50-128 Blade ppc valve — Structure............................ 10-136
Accumulator assembly - Remove......... 50-124,50-125 Blade relief pressure - Test................................. 30-56
Accumulator assembly - Remove/Install...........50-124 Blade relief pressure - Test with testing tools......30-58
Actions if fire occurs............................................00-29 Boom cylinder and bucket cylinder - Test the parts
Adjusting menu (Pump Absorption Torque) - Adjust.... causing hydraulic drift.................................. 30-85
...................................................................30-145 Boom cylinder - Maintenance standard.............. 60-68
Adjustment Menu.............................................. 30-145 Boom cylinder - Test oil leakage......................... 30-87
Adjustment menu (Attachment EPC 2 Adjustment) - Boom swing cylinder - Maintenance standard.... 60-74
Adjust.........................................................30-146 Boom swing PPC valve.....................................10-138
Adjustment menu (Attachment EPC 3 Adjustment) - Boom swing PPC valve - Maintenance standard60-49
Adjust.........................................................30-147 Boom swing PPC valve - Structure...................10-138
Air cleaner - Check for clogging..........................40-28 Boom swing relief pressure - Test by using machine
AIR CONDITIONER COMPONENT................... 80-10 monitor.........................................................30-50
Air conditioner compressor belt - Check / Adjust ten- Boom swing relief pressure - Test with testing tools....
sion.............................................................. 30-32 .....................................................................30-52
Air conditioner compressor belt - Test/Adjust tension.. Boot-up system................................................... 10-10
.....................................................................30-32 Boot-up system - Layout drawing....................... 10-10
Air conditioner system...........................................80-9 Brake valve of swing motor - Function..............10-148
Air conditioner unit.............................................. 80-15 Brake valve of swing motor - Operation............10-149
Air conditioner unit assembly - Install............... 50-179 Bucket cylinder - Maintenance standard.............60-71
Air conditioner unit assembly - Remove........... 50-175 Bucket cylinder - Test oil leakage........................30-88
Air conditioner unit assembly - Remove/Install. 50-175 Bucket - Dimension.............................................60-67
Alternator belt - Adjust tension............................30-31
Alternator belt - Test/Adjust tension.................... 30-31 C
Alternator belt - Test tension............................... 30-31
Arm cylinder - Maintenance standard................. 60-69 Cab......................................................... 10-176,30-94

1
INDEX

Cab and its attachments................................... 50-149 Control valve - Hydraulic circuit diagrams and names
Carrier roller assembly - Assemble.....................50-92 of valves.......................................................10-84
Carrier roller assembly - Disassemble................ 50-91 Control valve - Introduction of LS pressure.........10-99
Carrier roller assembly - Disassemble/Assemble........ Control valve - Maintenance standard................ 60-32
.....................................................................50-91 Control valve merge-divider valve.....................10-105
Carrier roller - Maintenance standard................. 60-19 Control valve pressure compensation valve....... 10-95
Caution lamps displayed on machine monitor - Types. Control valve - Structure..................................... 10-72
.....................................................................10-35 Conversion table................................................. 00-75
Center swivel joint.............................................10-170 Cooling system................................................... 10-27
Center swivel joint assembly - Assemble.......... 50-111 Cooling system - Layout drawing........................10-27
Center swivel joint assembly - Disassemble..... 50-110 Cooling system - Maintenance standard.............60-10
Center swivel joint assembly - Disassemble/Assem- Cooling system - Specifications.......................... 10-28
ble.............................................................. 50-109 Counterbalance valve and check valve of travel motor
Center swivel joint assembly - Install................ 50-106 ...................................................................10-165
Center swivel joint assembly - Remove............ 50-105 Counterbalance valve and check valve of travel motor
Center swivel joint assembly - Remove/Install..50-105 - Operation.................................................10-165
Center swivel joint - Function............................10-170 Counterweight assembly - Install...................... 50-100
Center swivel joint - Maintenance standard........ 60-56 Counterweight assembly - Remove.................... 50-97
Center swivel joint - Structure........................... 10-170 Counterweight assembly - Remove/Install..........50-97
CHECKS BEFORE TROUBLESHOOTING........ 40-15 Cyclone assembly - Operation............................10-58
CLSS...................................................................10-50 Cylinder cut-out mode operation - Handle.......... 30-30
CLSS - Function..................................................10-51
CLSS - Structure.................................................10-50 D
Coating materials list...........................................50-13
Component parts of air conditioner system........ 80-15 Default Menu.....................................................30-132
Component parts of control system.................... 10-32 Default menu (Key-on Mode) - Set................... 30-132
Component parts of engine system.................... 10-26 Default setting menu (Auto idle stop timer fixing) - Set
Component parts of hydraulic system.................10-56 ...................................................................30-134
Component parts of swing system....................10-146 Default setting menu (Unit) - Set.......................30-133
Component parts of travel system.................... 10-160 Default value menu (With/Without Attachment) - Set...
Component parts of work equipment system....10-129 ...................................................................30-133
Compression pressure - Test.............................. 30-23 Deutsch connector - Disconnect/Connect...........00-54
Compressor........................................................ 80-17 Diagnostic Tests Menu......................................30-137
Compressor - Function....................................... 80-17 Diodes - Test..................................................... 30-161
Compressor specifications..................................80-17 Diode using analog tester - Test....................... 30-161
Compressor - Structure.......................................80-17 Diode using digital tester - Test.........................30-161
Condenser.......................................................... 80-19
Configuration and function of refrigeration cycle.80-12 E
CONFIGURATION DIAGRAM OF AIR CONDITION-
ER UNIT...................................................... 80-15 E-10 FUEL GAUGE DISPLAY DOES NOT MOVE
CONNECTOR CONTRACT IDENTIFICATION (FOR FROM MINIMUM OR MAXIMUM.............. 40-226
4D88E-7 ENGINE).......................................40-81 E-11 DISPLAY OF FUEL GAUGE DIFFERS FROM
Connector - Precautions for disconnection and con- ACTUAL FUEL LEVEL.............................. 40-228
nection......................................................... 00-50 E-12 ENGINE COOLANT TEMPERATURE GAUGE
Connectors list and layout...................................40-65 DISPLAY DOES NOT MOVE FROM MINIMUM
Connector with housing to rotate - Disconnect/ OR MAXIMUM........................................... 40-229
Connect....................................................... 00-60 E-13 DISPLAY OF ENGINE COOLANT TEMPERA-
Connector with lock to push - Disconnect/Connect...... TURE GAUGE DIFFERS FROM ACTUAL
.....................................................................00-58 COOLANT TEMPERATURE......................40-230
Control circuit - Adjust oil pressure..................... 30-63 E-14 Some areas of machine monitor screen are not
Control circuit pressure - Test by using machine mon- displayed....................................................40-231
itor................................................................30-61 E-15 FUNCTION SWITCH DOES NOT OPERATE.....
Control circuit - Test/Adjust oil pressure..............30-61 ...................................................................40-232
Control circuit - Test oil pressure.........................30-62 E-16 Auto-decelerator is not operated or canceled
Control relief valve - Operation......................... 10-142 with lever....................................................40-233
Control system........................................10-29,30-104 E-17 When working mode is changed, setting of en-
Control system - Layout drawing........................ 10-29 gine and hydraulic pump is not changed... 40-234
Control valve....................................................... 10-72

2
INDEX

E-18 WHEN TRAVEL SPEED SELECTION IS Electrical circuit diagram..................................... 90-19

CHANGED, ACTUAL TRAVEL SPEED DOES Electrical circuit diagram (cab spec) (1/6)...........90-43
NOT CHANGE...........................................40-235 Electrical circuit diagram (cab spec) (2/6)...........90-45
E-19 ALARM BUZZER DOES NOT SOUND....40-237 Electrical circuit diagram (cab spec) (3/6)...........90-47
E-1 Engine does not start (engine does not crank))..... Electrical circuit diagram (cab spec) (4/6)...........90-49
...................................................................40-208 Electrical circuit diagram (cab spec) (5/6)...........90-51
E-20 ALARM BUZZER CANNOT BE CANCELED...... Electrical circuit diagram (cab spec) (6/6)...........90-53
...................................................................40-238 ELECTRICAL CIRCUIT DIAGRAM (CAB SPECIFI-
E-21 Service meter is not displayed, while starting CATIONS, QUICK COUPLER SPECIFICA-
switch is in off position............................... 40-239 TIONS) (1/6)................................................ 90-55
E-22 Service mode cannot be selected............ 40-240 ELECTRICAL CIRCUIT DIAGRAM (CAB SPECIFI-
E-23 ALL OF WORK EQUIPMENTS, SWING, AND CATIONS, QUICK COUPLER SPECIFICA-
TRAVEL MECHANISM DO NOT MOVE....40-241 TIONS) (2/6)................................................ 90-57
E-24 All of work equipment, swing, and travel mecha- ELECTRICAL CIRCUIT DIAGRAM (CAB SPECIFI-
nism do not lock.........................................40-243 CATIONS, QUICK COUPLER SPECIFICA-
E-25 ALARM DOES NOT SOUND DURING TRAVEL TIONS) (3/6)................................................ 90-59
...................................................................40-245 ELECTRICAL CIRCUIT DIAGRAM (CAB SPECIFI-
E-26 ALARM DOES NOT STOP SOUNDING WHILE CATIONS, QUICK COUPLER SPECIFICA-
MACHINE IS STOPPED............................40-247 TIONS) (4/6)................................................ 90-61
E-27 HORN DOES NOT SOUND..................... 40-248 ELECTRICAL CIRCUIT DIAGRAM (CAB SPECIFI-
E-28 HORN DOES NOT SOUND (FOR PROPOR- CATIONS, QUICK COUPLER SPECIFICA-
TIONAL LEVER SPEC)............................. 40-250 TIONS) (5/6)................................................ 90-63
E-29 HORN DOES NOT STOP SOUNDING.... 40-252 ELECTRICAL CIRCUIT DIAGRAM (CAB SPECIFI-
E-2 ENGINE DOES NOT START (FUEL FEED CATIONS, QUICK COUPLER SPECIFICA-
PUMP SYSTEM)....................................... 40-214 TIONS) (6/6)................................................ 90-65
E-30 HORN DOES NOT STOP SOUNDING (FOR Electrical circuit diagram (canopy spec) (1/5)..... 90-23
PROPORTIONAL LEVER SPEC)..............40-254 Electrical circuit diagram (canopy spec) (2/5)..... 90-25
E-31 Working lamp or travel lamp does not light up Electrical circuit diagram (canopy spec) (3/5)..... 90-27
(Canopy spec)........................................... 40-256 Electrical circuit diagram (canopy spec) (4/5)..... 90-29
E-32 None of working lamp, travel lamp, or additional Electrical circuit diagram (canopy spec) (5/5)..... 90-31
lamp does not light up (Cab spec)............. 40-260 ELECTRICAL CIRCUIT DIAGRAM (CANOPY SPEC-
E-33 WHEN WIPER SWITCH IS OPERATED, WIND- IFICATIONS, QUICK COUPLER SPECIFICA-
SHIELD WIPER DOES NOT OPERATE... 40-264 TIONS) (1/5)................................................ 90-33
E-34 WHEN WINDOW WASHER SWITCH IS OPER- ELECTRICAL CIRCUIT DIAGRAM (CANOPY SPEC-
ATED, WINDOW WASHER DOES NOT OPER- IFICATIONS, QUICK COUPLER SPECIFICA-
ATE............................................................ 40-266 TIONS) (2/5)................................................ 90-35
E-35 Travel indicator is not displayed properly with ELECTRICAL CIRCUIT DIAGRAM (CANOPY SPEC-
monitoring function.................................... 40-268 IFICATIONS, QUICK COUPLER SPECIFICA-
E-36 SWING OR ARM IN IS NOT DISPLAYED NOR- TIONS) (3/5)................................................ 90-37
MALLY IN MONITORING FUNCTION.......40-269 ELECTRICAL CIRCUIT DIAGRAM (CANOPY SPEC-
E-37 Work equipment is not displayed normally in IFICATIONS, QUICK COUPLER SPECIFICA-
monitoring function.................................... 40-270 TIONS) (4/5)................................................ 90-39
E-38 KOMTRAX system does not operate normally.... ELECTRICAL CIRCUIT DIAGRAM (CANOPY SPEC-
...................................................................40-272 IFICATIONS, QUICK COUPLER SPECIFICA-
E-3 Automatic preheating system does not work......... TIONS) (5/5)................................................ 90-41
...................................................................40-216 Electrical equipment - Check.............................. 40-45
E-4 When starting switch is turned to on position, ma- Electrical system............................................... 50-187
chine monitor displays nothing.................. 40-218 Electrical system - Preparation for troubleshooting......
E-5 Engine coolant temperature monitor lights up in .....................................................................40-53
white while engine is running.....................40-221 Electric circuit diagram symbol list...................... 90-19
E-6 Charge level monitor lights up in red while engine Engine / Cooling system........................... 30-17,50-23
is running................................................... 40-222 Engine and cooling system................................... 60-9
E-7 Fuel level monitor lights up in red while engine is Engine and main pump assembly - Install.......... 50-52
running.......................................................40-223 Engine and main pump assembly - Remove...... 50-46
E-8 Engine coolant temperature monitor lights up in Engine and main pump assembly - Remove/Install.....
red while engine is running........................ 40-224 .....................................................................50-46
E-9 Engine oil pressure monitor lights up in red while Engine and plump combined control system...... 10-53
engine is running....................................... 40-225

3
INDEX

Engine and plump combined control system - Func- FAILURE CODE [DHS1MA]..............................40-172
tion............................................................... 10-54 FAILURE CODE [DHS5MA]..............................40-174
Engine and pump combined control - System dia- FAILURE CODE [DKULKA].............................. 40-176
gram.............................................................10-53 FAILURE CODE [DKULKB].............................. 40-178
Engine controller assembly - Install.................. 50-188 FAILURE CODE [DKULKY].............................. 40-180
Engine controller assembly - Remove.............. 50-187 FAILURE CODE [DV00KB]...............................40-182
Engine controller assembly - Remove/Install....50-187 FAILURE CODE [DV20KB]...............................40-183
Engine control system.........................................10-16 FAILURE CODE [DW43KA]..............................40-185
Engine control system - Function........................10-17 FAILURE CODE [DW43KB]..............................40-187
Engine control system - System diagram........... 10-16 FAILURE CODE [DW43KY]..............................40-189
Engine speed - Test............................................ 30-17 FAILURE CODE [DW4CKY]............................. 40-190
Engine - Standard value table...............................20-9 FAILURE CODE [DXA8KA].............................. 40-192
Engine system.................................................... 10-15 FAILURE CODE [DXA8KB].............................. 40-194
Engine system - Layout drawing.........................10-15 FAILURE CODE [DXE7KA].............................. 40-196
Engine - Test oil pressure................................... 30-25 FAILURE CODE [DXE7KB].............................. 40-198
Exhaust gas color - Test......................................30-19 FAILURE CODE [DXE7KY].............................. 40-200
Exhaust gas color - Test by smoke meter........... 30-20 FAILURE CODE [DXEAKA].............................. 40-202
Exhaust gas color - Test with handy smoke checker... FAILURE CODE [DXEAKB].............................. 40-204
.....................................................................30-19 FAILURE CODE [DXEAKY].............................. 40-206
Failure codes table..............................................40-95
F Final drive case - Check oil level........................ 40-45
Floor - Cab specification - Close.......................30-102
FAILURE CODE [989L00].................................40-105 Floor - Cab specification - Open......................... 30-98
FAILURE CODE [989M00]................................40-106 Floor - Canopy specification - Close................. 30-100
FAILURE CODE [989N00]................................ 40-107 Floor - Canopy specification - Open................... 30-95
FAILURE CODE [AQ20R1]...............................40-108 Floor - Close..................................................... 30-100
FAILURE CODE [B@BCNS].............................40-109 Floor frame assembly (canopy specification) - Install..
FAILURE CODE [D19JKZ]................................40-110 ...................................................................50-159
FAILURE CODE [D811MC]............................... 40-113 Floor frame assembly (canopy specification) - Re-
FAILURE CODE [D862KA]............................... 40-114 move.......................................................... 50-156
FAILURE CODE [D8ALKA]............................... 40-115 Floor frame assembly (canopy specification) - Re-
FAILURE CODE [D8ALKB]............................... 40-117 move/Install................................................50-156
FAILURE CODE [D8AQKR].............................. 40-119 Floor - Open........................................................30-95
FAILURE CODE [DAF0KT]...............................40-121 Floor - Open / Close............................................30-94
FAILURE CODE [DAF0MB].............................. 40-122 Foreword, Safety, Basic information................... 00-17
FAILURE CODE [DAF0MC]..............................40-123 Front window assembly - Install........................50-173
FAILURE CODE [DAF3KK]...............................40-124 Front window assembly - Remove....................50-172
FAILURE CODE [DAF9KQ].............................. 40-126 Front window assembly - Remove/Install......... 50-172
FAILURE CODE [DAFGMC]............................. 40-127 Fuel - Check level and type................................ 40-19
FAILURE CODE [DAFLKA]...............................40-128 Fuel circuit - Check for leakage.......................... 30-29
FAILURE CODE [DAFLKB]...............................40-130 Fuel circuit - Test leakage................................... 30-29
FAILURE CODE [DAFQKR]..............................40-132 Fuel control dial...................................................10-46
FAILURE CODE [DB2QKR]..............................40-133 Fuel control dial - Function..................................10-46
FAILURE CODE [DBH0MC]............................. 40-137 Fuel control dial - Structure.................................10-46
FAILURE CODE [DBH2KK].............................. 40-138 Fuel prefilter - Check...........................................40-20
FAILURE CODE [DBH5KP].................. 40-141,40-143 Fuel system - Bleed air............................. 30-27,40-45
FAILURE CODE [DBH9KQ]..............................40-145 Fuel system equipment - Precautions for handling......
FAILURE CODE [DBHLKA].............................. 40-147 .....................................................................00-43
FAILURE CODE [DBHLKB].............................. 40-149 Fuel tank assembly - Install................................ 50-61
FAILURE CODE [DBHQKR]............................. 40-151 Fuel tank assembly - Remove............................ 50-59
FAILURE CODE [DDNRKA]............................. 40-156 Fuel tank assembly - Remove/Install.................. 50-59
FAILURE CODE [DDNRKY]............................. 40-158 Function of auto-deceleration system................. 10-20
FAILURE CODE [DDNS00].............................. 40-160 FUNCTION OF CONDENSER........................... 80-19
FAILURE CODE [DDWLKA]............................. 40-162 Function of LCD (Liquid Crystal Display) display of
FAILURE CODE [DDWLKB]............................. 40-164 the machine monitor - Check.....................30-107
FAILURE CODE [DFB1KZ]...............................40-166 Function of service meter - Check.................... 30-107
FAILURE CODE [DFB3L8]............................... 40-168 Fuse - Location table.......................................... 40-91
FAILURE CODE [DFB5KZ]...............................40-170

4
INDEX

G H-3 TRAVEL OR BLADE DOES NOT OPERATE........

...................................................................40-276
General troubleshooting points........................... 40-12 H-40 Upper structure overruns excessively when it
stops swinging (both right and left)............ 40-324
H H-41 Upper structure overruns excessively when it
stops swinging (only one direction either right or
H-10 UNUSUAL NOISE IS HEARD FROM AROUND left).............................................................40-325
HYDRAULIC PUMP...................................40-283 H-42 Shock is large when upper structure stops
H-11 Engine speed drops largely or engine stops....... swinging.....................................................40-326
...................................................................40-284 H-43 Large unusual noise is heard when upper struc-
H-12 ALL WORK EQUIPMENTS SPEED OR POW- ture stops swinging.................................... 40-327
ER IS LOW................................................ 40-286 H-44 Swing drift on a slope is large (while swing park-
H-13 ALL WORK EQUIPMENTS AND BLADE ing brake is applied)...................................40-328
SPEED OR POWER IS LOW.................... 40-287 H-45 Swing drift on a slope is large (while swing park-
H-14 Blade does not operate............................ 40-288 ing brake is released)................................ 40-329
H-15 ALL WORK EQUIPMENT DOES NOT OPER- H-4 SWING OR BLADE DOES NOT OPERATE.........
ATE............................................................ 40-289 ...................................................................40-277
H-16 ALL WORK EQUIPMENT OR BLADE DO NOT H-5 All work equipment, travel, swing and blade
OPERATE.................................................. 40-290 speed or power is low................................ 40-278
H-17 Speed or power of boom is low................40-291 H-6 ALL WORK EQUIPMENT AND TRAVEL SPEED
H-18 Arm speed or power is low.......................40-293 OR POWER IS LOW................................. 40-279
H-19 Bucket speed or power is low.................. 40-294 H-7 TRAVEL AND BLADE SPEED OR POWER IS
H-1 ALL WORK EQUIPMENT, TRAVEL, SWING OR LOW...........................................................40-280
BLADE DO NOT OPERATE...................... 40-274 H-8 SWING AND BLADE SPEED OR POWER IS
H-20 Blade speed or power is low.................... 40-295 LOW...........................................................40-281
H-21 BOOM SWING SPEED OR POWER IS LOW.... H-9 FINE CONTROL PERFORMANCE OR RE-
...................................................................40-297 SPONSE IS POOR....................................40-282
H-22 WORK EQUIPMENT DOES NOT MOVE IN HANDLE COMPRESSOR OIL............................80-44
SINGLE OPERATION................................40-298 Handling refrigerant - Precautions........................ 80-9
H-23 Hydraulic drift of boom is large.................40-299 How to read electrical wire code......................... 00-61
H-24 Hydraulic drift of arm is large................... 40-300 How to read the shop manual............................. 00-17
H-25 Hydraulic drift of bucket is large............... 40-301 How to read this manual..................................... 50-11
H-26 Hydraulic drift of blade is large.................40-302 Hydraulic circuit - Bleed air.............30-90,30-91,40-45
H-27 Time lag of work equipment is large.........40-304 Hydraulic circuit diagram............................ 90-9,90-13
H-28 In combined operation of work equipment, HYDRAULIC CIRCUIT DIAGRAM (QUICK COU-
equipment having heavier load moves slower...... PLER SPECIFICATIONS) (1/2)................... 90-15
...................................................................40-305 HYDRAULIC CIRCUIT DIAGRAM (QUICK COU-
H-29 Machine does not travel straight.............. 40-306 PLER SPECIFICATIONS) (2/2)................... 90-17
H-2 ALL WORK EQUIPMENT OR TRAVEL DOES Hydraulic circuit diagram symbol list.....................90-9
NOT OPERATE......................................... 40-275 Hydraulic cylinder circuit - Release remaining pres-
H-30 MACHINE DOES NOT MOVE OFF STRAIGHT. sure..............................................................30-37
...................................................................40-308 Hydraulic oil - Check oil level.............................. 40-38
H-31 Machine is not steered well or steering power is Hydraulic oil cooler assembly - Install.................50-42
low............................................................. 40-309 Hydraulic oil cooler assembly - Remove.............50-39
H-32 Travel speed is low...................................40-311 Hydraulic oil cooler assembly - Remove/Install.. 50-39
H-33 BOTH SIDES OF CRAWLERS DO NOT MOVE. Hydraulic oil filter - Check................................... 40-43
...................................................................40-313 Hydraulic oil strainer - Check.............................. 40-42
H-34 One of tracks does not run.......................40-314 Hydraulic system................ 10-48,30-37,50-105,60-25
H-35 Travel speed does not change, or travel speed Hydraulic system - Layout drawing..................... 10-48
is too slow or fast....................................... 40-316 Hydraulic system - Release remaining pressure 30-37
H-36 Upper structure does not swing both to the right Hydraulic tank..................................................... 10-56
and left....................................................... 40-317 Hydraulic tank assembly - Install.......................50-115
H-37 Swings only in one direction.....................40-319 Hydraulic tank assembly - Remove...................50-112
H-38 Swing acceleration or swing speed is low in Hydraulic tank assembly - Remove/Install........ 50-112
both directions (right and left).................... 40-321 Hydraulic tank breather.......................................10-59
H-39 Swing acceleration performance is poor or Hydraulic tank breather - Function......................10-59
swing speed is slow in only one direction.. 40-323 Hydraulic tank breather - Structure..................... 10-59
Hydraulic tank - Maintenance standard.............. 60-25

5
INDEX

Hydraulic tank oil filler cap.................................. 10-58 LS bypass plug of control valve........................ 10-101
Hydraulic tank oil filler cap - Function................. 10-59 LS bypass plug of control valve - Function....... 10-101
Hydraulic tank oil filler cap - Structure................ 10-58 LS bypass plug of control valve - Operation..... 10-102
Hydraulic tank - Pressurization........................... 30-93 LS differential pressure - Test by using machine mon-
Hydraulic tank - Pressurize................................. 30-93 itor................................................................30-67
Hydraulic tank - Release remaining pressure..... 30-37 LS differential pressure - Test with testing tools..30-68
Hydraulic tank - Specifications............................10-57 LS introduction throttle of pressure compensation
Hydraulic tank - Structure................................... 10-56 valve of control valve................................... 10-98
LS introduction throttle of pressure compensation
I valve of control valve - Function.................. 10-98
LS introduction throttle of pressure compensation
Idler assembly - Assemble..................................50-86 valve of control valve - Operation................ 10-99
Idler assembly - Disassemble............................. 50-85 LS valve - Adjust................................................. 30-70
Idler assembly - Disassemble/Assemble............ 50-85
Idler cushion......................................................10-172
Idler cushion - Specifications............................ 10-172
M
Idler cushion - Structure....................................10-172 Machine controller...............................................10-42
Idler - Maintenance standard.............................. 60-16 Machine controller assembly - Install................50-190
Information described in troubleshooting table (H- Machine controller assembly - Remove............50-189
mode).........................................................40-273 Machine controller - Input and output signals..... 10-42
Information described in troubleshooting table (S- Machine controller - Remove/Install..................50-189
mode).........................................................40-330 Machine controller - Structure.............................10-42
Information in troubleshooting table..........40-63,80-21 Machine monitor................................................. 10-32
Inspection procedure before troubleshooting......40-17 Machine monitor assembly - Install...................50-193
Intake system equipment - Precautions for handling... Machine monitor assembly - Remove...............50-192
.....................................................................00-44 Machine monitor assembly - Remove/Install.... 50-192
Introduction of LS pressure in control valve - Function Machine monitor - Function................................ 10-32
...................................................................10-100 Machine monitor - Input and output signals........ 10-33
Introduction of LS pressure in control valve - Opera- Machine monitor - Operator mode function........ 10-38
tion............................................................. 10-101 Machine monitor - Service mode function...........10-39
Machine monitor - Set/Operate.........................30-104
K Machine monitor system..................................... 10-30
Machine monitor - System diagram.................... 10-30
KDPF assembly - Disassemble/Assemble..........50-64 Machine monitor - Types of gauges and meters.10-34
KOMTRAX setting display (GPS & Communication Machine monitor - Types of pilot lamps.............. 10-37
Status) - Check.......................................... 30-151 Machine posture / Procedure for measuring perform-
KOMTRAX setting display (Modem Information) - ance............................................................. 20-37
Confirm...................................................... 30-152 Machine - Standard value table.......................... 20-13
KOMTRAX setting display (Terminal Status) - Confirm Machine - Test swing relief pressure...................30-54
...................................................................30-151 Machine - Test swing relief pressure with testing tools
KOMTRAX Settings Menu................................ 30-151 .....................................................................30-55
KOMTRAX system..............................................10-31 Machine - Test travel relief pressure with testing tools.
KOMTRAX system diagram................................10-31 .....................................................................30-49
KOMTRAX system - Function.............................10-31 Main filter - Check............................................... 40-23
KOMTRAX terminal............................................ 10-40 Main pump.......................................................... 10-60
KOMTRAX terminal assembly - Install..............50-196 Main pump assembly - Install........................... 50-120
KOMTRAX terminal assembly - Remove..........50-195 Main pump assembly - Remove........................50-118
KOMTRAX terminal assembly - Remove/Install.......... Main pump assembly - Remove/Install............. 50-118
...................................................................50-195 Main pump - Function......................................... 10-63
KOMTRAX terminal - Function........................... 10-40 Main pump LS valve........................................... 10-70
KOMTRAX terminal - Input and output signals... 10-40 Main pump LS valve - Function.......................... 10-70
KOMTRAX terminal - Start up...........................30-155 Main pump - Maintenance standard................... 60-26
KOMTRAX terminal - Structure...........................10-40 Main pump - Operation....................................... 10-64
Main pump PC valve...........................................10-71
L Main pump PC valve - Function..........................10-71
Main pump servo valve....................................... 10-66
Logic valve of control valve...............................10-103 Main pump servo valve - Maintenance standard 60-27
Logic valve of control valve - Function..............10-103 Main pump servo valve - Operate.......................10-67
Logic valve of control valve - Operation............10-104

6
INDEX

Main pump servo valve - Structure..................... 10-66 Power train..........................................................50-65

Main pump - Structure........................................ 10-60 Power train system................................... 30-34,60-11
Maintenance mode setting - Operate................30-126 PPC accumulator circuit - Release remaining pres-
Maintenance record - Confirm.......................... 30-125 sure..............................................................30-37
Merge-divider valve control valve - Function.... 10-105 PPC lock system...............................................10-124
Merge-divider valve of control valve - Operation.......... PPC lock system - Function..............................10-125
...................................................................10-107 PPC lock system - System diagram..................10-124
Method for disconnecting and connecting connector PPC valve - Test outlet pressure.........................30-74
with lock to pull............................................ 00-57 PPC valve - Test outlet pressure by using testing
METHOD FOR TESTING OIL PRESSURE OF CON- tools............................................................. 30-77
TROL CIRCUIT............................................30-61 PPC valve - Test outlet pressure with testing tools......
Motor part of Travel motor ................................10-163 .....................................................................30-74
Motor part of travel motor - Operation...............10-163 PPC valve - Test the parts causing hydraulic drift........
Multi-control valve............................................. 10-143 .....................................................................30-86
Multi-control valve - Structure........................... 10-143 Practical use of KOMTRAX.................................00-45
PRECAUTIONS FOR DISCONNECTING AND CON-
O NECTING HOSES AND TUBES IN AIR CONDI-
TIONER PIPINGS........................................80-42
Oil flow adjuster system for attachment............ 10-127 Precautions for disposing of waste materials......00-30
Oil flow adjuster system for attachment - Function...... Precautions for handling electrical equipment.... 00-41
...................................................................10-128 Precautions for handling hydraulic equipment.... 00-31
Oil flow adjuster system for attachment - System dia- Precautions to prevent fire.................................. 00-27
gram...........................................................10-127 Pre-defined Monitoring information - Check...... 30-111
Oil pan - Check engine oil level.......................... 40-26 Pre-defined Monitoring items - Table................ 30-112
Oil pressure in pump PC control circuit - Adjust. 30-65 Pressure compensation valve of control valve - Func-
Oil - Test leakage................................................ 30-87 tion............................................................... 10-95
Operator's cab assembly (cab specification) - Install... Pressure compensation valve of control valve - Oper-
...................................................................50-152 ation............................................................. 10-96
Operator's cab assembly (cab specification) - Re- Pressure compensation valve of control valve - Sur-
move.......................................................... 50-149 face area ratio..............................................10-97
Operator's cab assembly (cab specification) - Re- PROCEDURE FOR TESTING AND TROUBLE-
move/Install................................................50-149 SHOOTING..................................................40-56
Operator's cab glass (adhered glass) - Install.. 50-164 PTO.....................................................................10-26
Operator's cab glass (adhered glass) - Remove.......... PTO - Function....................................................10-26
...................................................................50-163 PTO - Maintenance standard................................60-9
Operator's cab glass (adhered glass) - Remove/ PTO - Structure...................................................10-26
Install......................................................... 50-162 Pump LS control circuit - Test/Adjust oil pressure........
Operator's seat - Install..................................... 50-184 .....................................................................30-67
Operator's seat - Remove................................. 50-184 Pump PC control circuit - Adjust pressure.......... 30-65
Operator's seat - Remove/Install...................... 50-184 Push-pull type coupler - Disconnect/Connect..... 00-46
Operator mode..................................................30-107
Overheat prevention system............................... 10-22
Overheat prevention system - Function.............. 10-23
R
Overheat prevention system - System diagram..10-22 Radiator assembly - Install..................................50-35
Radiator assembly - Remove..............................50-32
P Radiator assembly - Remove/Install................... 50-32
Receiver drier......................................................80-20
Parking brake of travel motor - Operation.........10-165 Receiver drier - Function.....................................80-20
PC45MR-5 - Specifications.................................01-15 Receiver drier specifications............................... 80-20
PC55MR-5 - Specifications.................................01-19 Receiver drier - Structure....................................80-20
PC-EPC valve- Maintenance standard............... 60-28 Recoil spring assembly - Assemble.................... 50-81
Phone number entry setting - Operate..............30-130 Recoil spring assembly - Disassemble............... 50-80
Pilot circuit accumulator.................................... 10-144 Recoil spring assembly - Disassemble/Assemble........
Pilot circuit accumulator - Function................... 10-144 .....................................................................50-80
Pilot circuit accumulator - Specifications...........10-144 Refrigeration cycle - Outline................................80-13
Pilot circuit accumulator - Structure.................. 10-144 Related information on troubleshooting.............. 40-12
Piping - Precautions for disconnection and connec- Reservoir tank - Check coolant level.................. 40-27
tion............................................................... 00-34 Revolving frame assembly - Install..................... 50-95

7
INDEX

Revolving frame assembly - Remove................. 50-94 Specification drawing - PC45MR-5....................... 01-9

Revolving frame assembly - Remove/Install.......50-94 Specification drawing - PC55MR-5..................... 01-11
Road liner - Maintenance standard.....................60-23 SPECIFICATIONS OF AIR CONDITIONER....... 80-11
ROPS cab......................................................... 10-176 SPECIFICATIONS OF CONDENSER................ 80-19
ROPS cab - Function........................................ 10-176 Sprocket - Maintenance standard....................... 60-14
ROPS cab - Structure....................................... 10-176 Standard tightening torque table.........................00-68
Rubber shoe - Maintenance standard.................60-24 Standard value table for engine: PC45MR-5........ 20-9
Standard value table for engine: PC55MR-5...... 20-11
S Standard value table for machine: PC45MR-5... 20-13
Standard value table for machine: PC55MR-5... 20-25
S-10 Engine oil consumption is excessive........40-343 Starting motor assembly - Install.........................50-31
S-11 Oil becomes contaminated quickly........... 40-344 Starting motor assembly - Remove.....................50-30
S-12 Fuel consumption is excessive.................40-345 Starting motor assembly - Remove/Install.......... 50-30
S-13 Oil is in coolant (Or coolant spurts back or cool- STRUCTURE OF CONDENSER........................80-19
ant level goes down)..................................40-346 Supply pump assembly - Install.......................... 50-26
S-14 Oil pressure drops.................................... 40-347 Supply pump assembly - Remove...................... 50-23
S-15 Fuel mixes into engine oil.........................40-349 Supply pump assembly - Remove/Install............50-23
S-16 Water mixes into engine oil (milky)...........40-350 Surface area ratio of pressure compensation valve of
S-17 Coolant temperature rises too high (overheat- control valve - Function................................10-97
ing).............................................................40-351 Swing, Blade circuits - Test/Adjust oil pressure.. 30-54
S-18 Unusual noise is heard.............................40-352 Swing and blade valve of control valve............. 10-112
S-19 Vibration is excessive...............................40-353 Swing and blade valve of control valve - Operation.....
S-1 Engine does not crank when starting switch is ................................................................... 10-113
turned to start position............................... 40-331 Swing and blade valves of control valve - Structure....
S-20 Air cannot be bled from fuel circuit........... 40-354 ................................................................... 10-112
S-2 Engine cranks but no exhaust smoke comes out.. Swing circle.......................................................10-155
...................................................................40-332 Swing circle assembly - Install............................ 50-78
S-3 Fuel is being injected but engine does not start Swing circle assembly - Remove........................ 50-78
(misfiring: engine cranks but does not start)......... Swing circle assembly - Remove/Install..............50-78
...................................................................40-333 Swing circle bearing - Test clearance................. 30-34
S-4 Engine startability is poor........................... 40-334 Swing circle - Function......................................10-155
S-5 Engine does not pick up smoothly..............40-336 Swing circle - Maintenance standard.................. 60-11
S-6 Engine stops during operation....................40-338 Swing circle - Specifications............................. 10-155
S-7 Engine runs rough or is unstable................40-339 Swing circle - Structure..................................... 10-155
S-8 Engine lacks power.................................... 40-340 Swing circuit/Blade circuit - Adjust oil pressure............
S-9 KDPF gets clogged in a short time.............40-342 ...........................................................30-54,30-59
Safety notice for operation.................................. 00-19 Swing machinery...............................................10-153
Seat belt - Install............................................... 50-186 Swing machinery assembly - Assemble............. 50-74
Seat belt - Remove........................................... 50-186 Swing machinery assembly - Disassemble.........50-71
Seat belt - Remove/Install.................................50-186 Swing machinery assembly - Disassemble/Assemble.
Self-define monitoring information - Check....... 30-115 .....................................................................50-71
Self-define monitoring - Table........................... 30-117 Swing machinery - Function..............................10-154
Sequence of events in troubleshooting...............40-13 Swing machinery - Maintenance standard..........60-12
Service message - Display............................... 30-153 Swing machinery - Specifications..................... 10-153
Service mode.................................................... 30-110 Swing machinery - Structure.............................10-153
Service mode - Operate.................................... 30-110 Swing modulating relief valve of swing motor... 10-152
Setting inducement and changing maintenance pass- Swing modulating relief valve of swing motor - Func-
word - Function.......................................... 30-107 tion............................................................. 10-152
Sketch of tools - Testing and adjusting............... 30-15 Swing modulating relief valve of swing motor - Oper-
Slide lock type connector - Disconnect/Connect.00-55 ate..............................................................10-152
Solenoid valve - Operate.................................... 30-73 Swing motor...................................................... 10-146
Solenoid valve - Operation................................10-141 Swing motor and swing machinery assembly - Install..
Solenoid valve outlet pressure - Test.................. 30-71 .....................................................................50-70
Solenoid valve - Test outlet pressure........30-71,30-72 Swing motor and swing machinery assembly - Re-
Special tools - List...............................................50-17 move............................................................ 50-69
Special tools - Sketches......................................50-22 Swing motor and swing machinery assembly - Re-
Specification............................................... 01-9,01-15 move/Install..................................................50-69
Specification drawing............................................ 01-9 Swing motor - Brake valve................................ 10-148

8
INDEX

Swing motor circuit - Release remaining pressure....... Travel control system - Function....................... 10-158
.....................................................................30-42 Travel control system - System diagram...........10-158
Swing motor - Function..................................... 10-148 Travel deviation - Adjust......................................30-82
Swing motor - Maintenance standard................. 60-29 Travel deviation - Test......................................... 30-82
Swing motor - Operation................................... 10-148 Travel deviation - Test/Adjust.............................. 30-82
Swing motor - Specifications.............................10-147 Travel junction valve of control valve................ 10-109
Swing motor - Structure.................................... 10-146 Travel junction valve of control valve - Function..........
Swing parking brake cancel circuit of control valve...... ...................................................................10-109
................................................................... 10-114 Travel junction valve of control valve - Operation........
Swing parking brake cancel circuit of control valve - ................................................................... 10-110
Operation................................................... 10-114 Travel motor...................................................... 10-160
Swing parking brake of swing motor................. 10-150 Travel motor and final drive assembly - Install....50-67
Swing parking brake of swing motor - Operate.10-150 Travel motor and final drive assembly - Remove50-65
Swing parking brake - Test release pressure......30-80 Travel motor and final drive assembly - Remove/
Swing parking brake - Test release pressure with ma- Install........................................................... 50-65
chine monitor............................................... 30-80 Travel motor - Automatic gear shift valve..........10-166
Swing relief pressure - Adjust............................. 30-59 Travel motor circuit - Release remaining pressure.......
Swing system....................................................10-145 .....................................................................30-42
Swing system - Layout drawing........................ 10-145 Travel motor - Function..................................... 10-162
SYMPTOMS OF FAILURE AND TROUBLESHOOT- Travel motor - Maintenance standard................. 60-31
ING NUMBERS........................................... 40-59 Travel motor parking brake............................... 10-165
System operating lamp - System........................ 10-12 Travel motor - Specifications.............................10-162
System operating lamp - System diagram.......... 10-12 Travel motor - Structure.................................... 10-160
System operating lamp system - Function..........10-12 Travel pilot pressure detection circuit of control valve..
................................................................... 10-116
T Travel pilot pressure detection circuit of control valve
- Function................................................... 10-116
Table of fuel, coolant, and lubricants...................01-27 Travel pilot pressure detection circuit of control valve
T-boxes and T-adapters list.................................40-85 - Operation................................................. 10-116
Terms for maintenance standard - Explanation.. 00-65 Travel PPC valve.............................................. 10-168
Testing and adjusting - Related information........ 30-11 Travel PPC valve assembly - Assemble........... 50-134
Testing in accordance with testing procedure..... 40-19 Travel PPC valve assembly - Disassemble...... 50-133
Testing menu (cylinder cut-out operation) - Operate.... Travel PPC valve assembly - Disassemble/Assemble.
...................................................................30-137 ...................................................................50-133
Testing menu (KDPF memory reset) - Reset.... 30-140 Travel PPC valve - Maintenance standard..........60-51
Testing menu (Rail pressure memory reset) - Operate Travel PPC valve - Structure.............................10-168
...................................................................30-142 Travel relief pressure - Test.................................30-48
Testing menu (regeneration for service) - Operate...... Travel system....................................................10-156
...................................................................30-138 Travel system - Layout drawing........................ 10-156
The parts causing hydraulic drift in work equipment - Triple shoe - Maintenance standard value.......... 60-22
Test.............................................................. 30-85 Troubleshooting by failure code (display of code)........
Tilt type floor......................................................10-177 ...................................................................40-105
Tilt type floor - Function.....................................10-177 Troubleshooting for hydraulic and mechanical sys-
Tilt type floor - Structure....................................10-177 tems (H mode)........................................... 40-273
Tools for testing and adjusting - List....................30-11 Troubleshooting of electrical system (E-mode).40-208
Track frame and idler cushion - Maintenance stand- Troubleshooting of engine (S-mode).................40-330
ard................................................................60-15 Type 1 push-pull type coupler - Disconnect/Connect...
Track roller assembly - Assemble....................... 50-89 .....................................................................00-46
Track roller assembly - Disassemble.................. 50-88 Type 2 push-pull type coupler - Disconnect/Connect...
Track roller assembly - Disassemble/Assemble. 50-88 .....................................................................00-47
Track roller - Maintenance standard................... 60-18 Type 3 push-pull type coupler - Disconnect/Connect...
Track shoe assembly - Install..............................50-83 .....................................................................00-48
Track shoe assembly - Separate........................ 50-83
Track shoe assembly - Separate/Install.............. 50-83
Track shoe - Maintenance standard....................60-20
U
Track tension - Adjust......................................... 30-35 Undercarriage and frame... 10-171,30-35,50-80,60-15
Track tension - Test.............................................30-35 Undercarriage - Layout drawing........................10-171
Track - Test/Adjust tension..................................30-35 Undercarriage - Specifications..........................10-171

9
INDEX

Unload pressure - Adjust.................................... 30-53 Work equipment pilot pressure detection circuit of
Unload pressure - Test by using machine monitor....... control valve............................................... 10-115
.....................................................................30-43 Work equipment pilot pressure detection circuit of
Unload pressure - Test with testing tools............ 30-44 control valve - Function.............................. 10-115
Unload valve of control valve.............................. 10-87 Work equipment pilot pressure detection circuit of
Unload valve of control valve - Function............. 10-87 control valve - Operation............................ 10-115
Unload valve of control valve - Operation........... 10-91 Work equipment PPC valve / Swing PPC valve - Ad-
just play........................................................30-79
V Work equipment PPC valve assembly - Assemble......
...................................................................50-131
Valve - Adjust clearance..................................... 30-22 Work equipment PPC valve assembly - Disassemble.
Valve control - Structure....................................10-122 ...................................................................50-130
Valve - Test/Adjust clearance..............................30-21 Work equipment PPC valve assembly - Disassemble/
Valve - Test clearance.........................................30-21 Assemble................................................... 50-130
Voltage circuit of engine controller - Handle..... 30-160 Work equipment - Structure.............................. 10-173
Work equipment system....................................10-118
W Work equipment system - Layout drawing........ 10-118
Work equipment - Test relief pressure................ 30-45
WATER SEPARATOR - CHECK / DRAIN WATER Work equipment - Test relief pressure with testing
AND SEDIMENT..........................................40-22 tools............................................................. 30-47
Weight table........................................................ 01-23 Working range.....................................................01-13
Weight table - PC45MR-5................................... 01-23 Working range drawing - PC45MR-5.................. 01-13
Weight table - PC55MR-5................................... 01-25 Working range drawing - PC55MR-5.................. 01-14
Work equipment......................... 10-173,50-136,60-57
Work equipment, Swing, Travel circuits - Test/Adjust
oil pressure.................................................. 30-43
Work equipment, Travel circuits - Test oil pressure......
.....................................................................30-43
Work equipment / Travel - Adjust relief pressure 30-53
Work equipment and swing PPC valve.10-129,10-132
Work equipment and swing PPC valve - Maintenance
standard.......................................................60-44
Work equipment and swing PPC valve - Structure......
...................................................................10-129
Work equipment and travel automatic lock system......
...................................................................10-126
Work equipment and travel automatic lock system -
Function..................................................... 10-126
Work equipment and travel automatic lock system -
Operation................................................... 10-126
Work equipment assembly - Install................... 50-137
Work equipment assembly - Remove............... 50-136
Work equipment assembly - Remove/Install.....50-136
Work equipment circuits, travel circuits, and swing cir-
cuits - Adjust oil pressure.............................30-52
Work equipment clearance adjustment shim.... 10-175
Work equipment clearance adjustment shim - Func-
tion............................................................. 10-175
Work equipment cylinder assembly - Assemble..........
...................................................................50-144
Work equipment cylinder assembly - Disassemble......
...................................................................50-141
Work equipment cylinder assembly - Disassemble/
Assemble................................................... 50-140
Work equipment - Function...............................10-174
Work equipment linkage - Maintenance standard........
.....................................................................60-57

10
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